Architectural Roofing & Waterproofing Volume 1 2011

2011, Volume 1

ROOM GROW TO

ROOFTOP VEGETABLE GARDENS

• Waterproofing Concrete Is Essential

• White Elastomeric Roof Coatings

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ROOFING &WATERPROOFING 2011, Vol. 1

2011, Volume 1

About the Cover:

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ROOM OM GROW OW OW TO

ROOFTOP VEGETABLE GARDENS

s 7ATERPROOlNG #ONCRETE)S %SSENTIAL

s 7HITE %LASTOMERIC 2OOF#OATINGS

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Rooftop vegetable gardens like this one on top of the Gary Comer Youth Center in Chicago provide new opportunities in urban environments. (Photo courtesy of American Hydrotech, Inc.)

Features 10 Fighting for City Hall . . . . . . . . . . . . . . . . . . . . 16 Room to Grow. . . . . . . . . . . . . . . . . . . . . . . 20 Green Shipping. . . . . . . . . . . . . . . . . . . . . . 22 White Elastomeric Roof Coatings . . . . . . . 24 Form & Function. . . . . . . . . . . . . . . . . . . . . 29 Waterproofing Concrete Is Essential . . . .

22 Web Exclusives Available online at www.arwmag.com:

New High-Performance Roofing at George School Makes the Grade • Cool Roofs 101 • The Value of Solar

Columns 4 Legally Speaking by Richard Alaniz . . . . . 32 Editor's Note . . . . . . . . . . . . . . . . . . . . . . . . 35 A Word From the Publisher . . . . . . . . . . . . . .

Departments 6 Details: Roofing . . . . . . . . . . . . . . . . . . . . . . 8 Details: Waterproofing . . . . . . . . . . . . . . . . 9 Advertiser Index . . . . . . . . . . . . . . . . . . . 35 Roofing and Waterproofing Codes . . . . . . .

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{ A Word From the Publisher New and Improved for 2011

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elcome to the first of three print editions of Architectural Roofing & Waterproofing this year. When we first launched ARW four years ago, our goal was to create a platform for the architect that focused on the unique issues and most innovative products involved in roofing, waterproofing and building envelope systems. In 2011, we are continuing to expand our vision, and we’re pleased to announce the following additions and improvements: • New Associate Publisher Liz Obloy. Liz was formerly with BNP Media’s sister publications Environmental Design + Construction and Sustainable Facility, and she brings a wealth of experience in green design and construction. • Expanded topics and speakers for the ARW monthly CEU webinar series. Make sure to see what’s coming at www.arwmag.com/webinars. All ARW webinars are AIA accredited, and some green-focused sessions are also accredited with GBCI. • New look and expanded content for our website, monthly e-newsletters and print/digital editions. • We’ll also be coming out with a new app with special content. ARW is primarily a digital technical resource. Yes, we do print three issues per year. But to stay in touch regularly, I invite you to sign up for our monthly e-newsletters at www.arwmag.com. Q Liz Obloy is ARW 's new Associate Publisher We want to hear from you. Let us know if there are topics or interesting projects you’d like us cover. If you are interested in being featured in an Architect Profile, please contact Chris King at [email protected]. Have an amazing 2011.

Jill Bloom, Group Publisher [email protected] dia

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TECHNOLOGY

{ Roofing&WaterproofingCodes

RoofingCode: Section 1503

Roofing Assemblies Section 1503.3 Coping. Parapet walls shall be properly coped with noncombustible, weatherproof materials of a width no less than the thickness of the parapet wall.

Code Interpretation This code implies that a separate waterproofing material is to be applied over the top of a parapet wall. The designer cannot leave the masonry, concrete or wood substrate exposed to the elements. This is a critical design and code element that is often overlooked. The top of the parapet wall is highly vulnerable to moisture infiltration.

Waterproofing can consist of any approved waterproofing material that is suitable to the existing substrate. Applications of sealants, flashings, masonry coverings or termination metals are acceptable. The most common type of parapet coping is a metal coping that is fabricated out of galvanized metal. Metal copings applied at the perimeter of the structure must be in compliance with ANSI/SPRI ES-1, which requires the use of tested and certified materials and states securement requirements based on the wind zone region of the structure.

WaterproofingCode: Section 1807

Dampproofing and Waterproofing 1807.4.1 Floor base course. Floors of basements, except as provided for in Section 1807.1.1, shall be placed over a floor base course not less than 4 inches (102 mm) in thickness that consists of gravel or crushed stone containing not more than 10 percent of material that passes through a No. 4 (4.75 mm) sieve. Exception: Where a site is located in well-drained gravel or sand/gravel mixture soils, a floor base course is not required.

Code Interpretation This section implies that a base course a minimum of four

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(4) inches (102 mm) thick is required under all basement floors. The base course shall consist of gravel or crushed stone that does not allow more than 10 percent passage through a No. 4 sieve, which is 4.75 mm. The only exception to this is if the basement floor is located in an area that is well drained through gravel or a sand and gravel mixture. Section 1807.1.1 defines a basement this way: “a basement is considered a story above grade plane if any portion of the basement wall is located above the ground level.” AR&W

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{ Details: Roofing Coping-to-Wall Termination SHEET METAL Z-FLASHING LAPPING TOP SADDLE FLANGE

Approx. 6"

METAL WALL CLADDING

SHEET METAL SADDLE FLASHING (Set In 2 Continuous Beads of Sealant) SLOPED TOP PARAPET WALL (e.g. Beveled Siding, Nail Or Screw to Wood Nailer.)

BASE FLASHING MEMBRANE (See Other Details For Description Of Different Substrate Conditions and Parapet Heights.)

COUNTERFLASHING

RAGGLE SET COUNTERFLASHING

A

FABRICATED SHEET METAL SADDLE FLASHING SHEET METAL COPING

SURFACE-MOUNTED COUNTERFLASHING

critical and often overlooked design detail is at the termination of a parapet coping at a wall. The most common mistake at this intersection is to allow the metal coping to but up to the wall without the application of termination metal. The omittance of the termination metal leaves an opening at the top of the coping and allows for moisture infiltration at the space between the parapet wall and the structural wall. The installation of the coping-to-wall termination provides waterproofing protection and allows for differential movement between the two construction components. Prior to the installation of the parapet coping, a metal f lashing material shall be adhered to the structural wall. The metal flashing shall lap the parapet wall. The top of the

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NOTES: 1. Dimensions shown are recommended minimums and are intended to be approximate to allow for reasonable tolerances due to field conditions. 2. Attach top of membrane wall flashing approximately 6" O.C. 3. See Appendix A for gauge or thickness guide for sheet metal flashing. 4. Continuous cleats are recommended when flashing face dimension exceeds 3 inches and in areas deemed high wind zone as categorized by local building code. 5. Certain components as depicted in these details may not be provided by the roofing contractor. 6. Pre-flashing the coping-to-wall termination with membrane flashing (e.g. with self-adhering membrane) is suggested prior to installation of sheet metal saddle flashing.

Q Coping-to-wall detail courtesy of the Western States Roofing Contractors Association.

metal flashing shall be terminated with a counterflashing that is either surface mounted or set in a reglet. The metal coping is then applied over the completed wall f lashing and secured in accordance with local wind zone requirements. (Perimeter metal coping materials must be in compliance with ANSI/SPRI ES-1 requirements.) A prefabricated sheet metal saddle flashing is applied at the junction of the structural wall and parapet wall to terminate exposed openings. The saddle flashing shall be set in two continuous beads of sealant. A bead of continuous sealant shall be applied at the top of the counterf lashing and the seams of the sheet metal saddle flashing. AR&W

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{

Details: Waterproofing

Plaza Drain Flashing

T

he waterproofing substrate must be properly prepared prior to the application of the plaza drain f lashing material. Any openings and /or defects ACCEPTABLE CONCRETE, ASPHALT, PAVER, in the substrate must be properly repaired. An excellent OR TILE OVERBURDEN source for designers is the inclusion of ASTM D-5295 as a standard for the identification and repair of any conANGLED RESIN FILL @ ALL MEMBRANE crete defects. In addition to the substrate preparation, TERMINATION POINTS (TYP.) some manufacturers require that primer be applied KEMPEROL FIELD MEMBRANE EXTENDED over the drain bowl to aid in the adhesion of the 6" MIN. OVER KEMPEROL DRAIN FLASHING. waterproofing membrane. (1) PLY KEMPEROL MEMBRANE FLASHING-EXTEND Apply a layer of the waterproofing flashing MINIMUM OF 3" INTO PREPARED AND PRIMED material over the substrate in accordance with DRAIN BOWL. the manufacturer’s requirements. The flashing PREPARE, LEVEL & PATCH SUBSTRATE AS shall be fully adhered to the substrate and shall REQUIRED W/APPROVED LEVELING COMPOUND extend a minimum of three PRIOR TO APPLICATION OF KEMPEROL PRIMER (3) inches into the prepared & MEMBRANE (TYP.) drain bowl. Apply a continuous bead of the manufacturer’s approved sealant at each termination point of the flashing material — in the bowl and over the substrate. Apply the waterproofing membrane material a minimum of six (6) inches 6" MIN. onto the waterproofing OVERLAP flashing material. Application shall be in compliance with the manufacturer’s installation and termination requirements. Note: Prior to the waterproofing application the WRAP DRAIN SLEEVE W/GEOTEXTILE FILTER collar of the drain assemFABRIC & EXTEND 12" MIN. INTO bly should be adjusted to HORIZONTAL PLANE ensure that it is flush with the substrate. AR&W ACCEPTABLE PLAZA DRAIN ASSEMBLY

Q Plaza drain flashing detail courtesy of Kemper System.

ADJUST COLLAR AS REQUIRED TO ASSURE TOP OF GRATE IS FLUSH W/PAVEMENT. PREPARE & PRIME DRAIN BOWL AS REQ'D. FOR KEMPEROL MEMBRANE APPLICATION.

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WATERPROOFING

CONCRETE E TIA IAL IS

by John D'Annunzio

T

here is a common misconception that concrete provides waterproofing capabilities. This supposition has led to moisture infiltration and structural damage with countless buildings. I have recently been involved with a high-profile project in which this misconception contributed to extensive and extremely costly interior damage. Although concrete in a perfect state will prevent moisture intrusion, there are several potential imperfections to concrete that limit its ability to prevent moisture intrusion throughout its service life. These imperfections can be present at the initial stages of the pour and also occur throughout the concrete’s service life. Waterproofing is required at belowgrade concrete surfaces for several reasons. The primary reason is to keep moisture from intruding into the facility. However, it is also required to pro-

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tect the structural contents from water infiltration that can cause structural damage to the concrete or corrosion to the embedded steel. Concrete is by design a porous material, and water can pass through it by hydrostatic pressure, water vapor gradient or capillary action. Water can also enter at cracks, structural defects or at improperly designed or installed joints. Waterproofing is also required to eliminate deterioration to the concrete that can occur from exterior and interior chemicals that are present at the building site.

Susceptibility to Chemicals Concrete is vulnerable to chemicals due to three of its primary composition characteristics: permeability, alkalinity, and reactivity. Permeability to liquids and gasses varies considerably with different types of concrete. Even the best concrete has some small degree of per-

meability. Permeability increases rapidly with an increasing water-cement ratio and with decreasing moisture-curing time. Penetration of f luids into the concrete is sometimes accompanied by chemical reactions with cement, aggregates, and/or embedded steel if it is present. Leaching of cement hydration compounds, deposition of extraneous crystals or crystalline reaction products can also degrade the system. The alkaline, hydrated Portland cement binder reacts with acidic substances. This reaction is usually accompanied by the formation and removal of soluble reaction products, resulting in disintegration of the concrete. When the reaction products are insoluble, deposits are formed on the concrete surface or in the concrete, causing a considerably reduced reaction rate. Usually the rate of attack will be increased with an increase in the concentration of aggressive agents in the solution.

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Waterproofing Concrete

The solutions can be alkaline, neutral, or acidic based on the pH factor of the solution. Neutral solutions have a pH of 7. Acid solutions have pH values less than 7 and alkaline solutions have values over 7. When the pH factor decreases from 7, the solution becomes more acidic and it will become more aggressive in its attack on concrete. The chemical agents’ physical state is also important. Dry solids do not attack dry concrete; however, they may attack a moist concrete. A moist, reactive solid can attack concrete in a similar fashion to an aggressive liquid or solution. Dry gases, if they are aggressive, may come

deposit that results may be the original substance or it may be some reaction that is formed in the concrete. The result is efflorescence that is seen on the concrete walls, brick or stone. Salt solutions can be more destructive to concrete through freeze and thaw cycles than water alone. Damage from water or salt solutions can be minimized by an adequate amount of intentionally

entrained air in the concrete. This will allow high-quality concrete to produce air bubbles of the correct size, spacing, and distribution. There are several chemicals that are destructive to concrete. These types of chemicals are often located in the soil or surrounding areas of a below grade structure. It is the designer’s responsibility to have a proper chemical analysis

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Q The waterproofing process involves members of several different trades, and designers must specify the role of each and define what constitutes proper substrate preparation. (Photo courtesy of Carlisle Coatings & Waterproofing.)

into contact with sufficient moisture within the concrete to make the attack possible. Moist, aggressive gasses tend to be more destructive. Alternate wetting and drying can be harmful to the concrete structure and can result in destruction due to an alkali-aggressive reaction. This occurs when the dissolved substances migrate through the concrete and deposit at or near a surface where evaporation occurs. The

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Waterproofing Concrete

{

“Seawater, perhaps largely because of its sulfate content, may be destructive to permeable concretes or those made with cement having high tricalcium aluminate content.”

of the soil conducted prior to design of the waterproofing system. The chemicals present may also be harmful to the waterproofing barrier. Some of the more destructive chemicals to concrete are acid waters, aluminum chloride, aluminum sulfate, ammonia vapors, ammonium sulfate, ammonium chloride, ferric sulfide and ferrous sulfate, which all can disintegrate concrete and attack the steel. In addition to chemical attacks from organic and mineral acids, certain acidcontaining or acid-producing substances such as industrial wastes, silage, fruit juices, sour milk, weak base salts and some untreated waters may also cause deterioration of concrete. Ammonium salts and animal wastes can also oxidize and attack the concrete, producing some deterioration. Many agents attack concrete and destructively alter its chemical composition by means of reaction mechanisms that are only partially or incompletely understood.

Seawater, perhaps largely because of its sulfate content, may be destructive to permeable concretes or those made with cement having high tricalcium aluminate content. The deterioration typically occurs from leaching of dissolving calcium from the concrete. Not all chemicals are harmful to concrete. Among the common neutral salts that do not attack concrete are most carbonates and nitrates, some chlorides, fluorides and silicates. Limewater is usually beneficial to concrete because it promotes hydration without removal of lime from the concrete. Other weak alkaline solutions are not usually harmful. Products derived from petroleum, when free of fatty oil additives or other potentially acidic materials, are normally harmless to mature concrete. Some of these materials can cause undesirable discoloration.

Points of Infiltration Waterproofing is required at concrete structures to keep moisture out of the facility and to protect the structural components of concrete and embedded reinforcing steel. One obvious problem is that concrete can crack before and after hardening, and cracks are susceptible to moisture infiltration. Prior to hardening, concrete can crack from construction movement, plastic or drying shrinkage, or from early frost damage. Concrete can crack after hardening from settlement, seismic forces, vibration, creep, excessive loading or deflection from soil movement. In addition to being a porous material, concrete is susceptible to moisture infiltration at a number of locations. Points of moisture infiltration include all concrete joints, control joints and expansion joints. Openings can also occur at tie rod holes, penetrations and structural connections. Internal drains are also entry points for moisture intrusion. Q Waterproofing is required at belowgrade concrete surfaces to keep moisture from entering the facility and causing structural damage to the concrete or embedded steel. (Photo courtesy of Carlisle Coatings & Waterproofing.)

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Waterproofing Concrete

There is always a debate regarding positive side versus negative side waterproofing. When considering this decision, one should always remember that it is the responsibility of waterproofing to protect the structure. This goal cannot be accomplished with negative side waterproofing. To be effective, waterproofing should always be applied to the positive hydrostatic pressure side of the structure. The installation of any system on the negative hydrostatic pressure side is to take the risk of the waterproofing system being pushed off or disbanded by moisture infiltrating the concrete in either vapor or liquid form. Waterproofing of the negative side of the structure also tends to bring any contaminants present in the ground moisture into the concrete mass.

Concrete Surface Defects An important factor affecting the performance of waterproofing systems is the quality of the concrete surface. A smooth surface essentially free of honeycombs, depressions, fins, holes, humps, dust, dirt, oils, and other surface contaminants is necessary to provide continuous support to the waterproofing material and good adhesion between the membrane and the substrate. Water pressure acting on unsupported material may cause it to extrude, deform and eventually rupture. Good adhesion between the concrete surface and the waterproofing membrane is also essential to prevent water migration and leakage if there are any openings or imperfections in the membrane or concrete surface. Form coatings or release agents and concrete curing membranes could interfere with the development of good adhesion and should be removed prior to the waterproofing application. The designer should specify proper substrate preparation in the concrete division of the specifications. Separate trades typically complete concrete placement and waterproofing application, and this can create confusion and cause problems. Opinions can differ on what constitutes proper concrete preparation and

whose responsibility it is to perform any repairs required before the waterproofing application. The designer can eliminate these issues by providing language stating that concrete placement and repair be completed in accordance with ASTM D 5925. This is an excellent reference guide that contains a list of remediation measures for identifying and repair-

ing fins, bug holes, form kick-outs and similar surfaces that are unsuitable for the application of waterproofing. Reference to this standard in the Concrete Section and Waterproofing Section will eliminate potential problems during the project. The designer should also require that the waterproofing contractor approve the surface in writing prior to installation.

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Waterproofing Concrete

Spec i f ic i s sues t hat mu s t be addressed in the design specifications include concrete repair af ter form removal and removal and repair of any surface defects that occur during construction. Precast concrete is normally produced in a shop operation. Sharp offsets between precast sections should be corrected as indicated for new castin-place concrete. Surface defects, including tie holes, should be repaired immediately af ter the forms have been removed. All honeycombed and defective concrete areas should be removed down to sound concrete. If chipping is necessary, the edges should be perpendicular to the surface or slightly undercut. No featheredges should be permitted. The area to be patched and a surrounding band of approximately 6 inches should be dampened to prevent absorption of water from the patching mortar. A bonding grout or bond coat should be prepared using a mix of approximately one part cement to one part fine sand that is mixed to a consistency of a thick cream. The mix should be evenly brushed into the surface. Fins, protrusions or similar irregularities projecting from the concrete surface should be removed back to the surface by chipping, hammering or wire brushing. Care should be exercised to obtain a reasonably planar surface for application of the waterproofing membrane system. Sharp offsets in the surface, such as those caused by formwork misalignment, should be mechanically abraded to provide gradual and smooth transitions between the offset surfaces. Some waterproofing systems do not require all concrete surfaces to be within the same plane as long as the transitions are gradual and smooth. The waterproofing manufacturer should be contacted for specific requirements in these cases.

Q Preparation requirements vary by the type of material and application methods used. It is important that the manufacturer’s requirements for substrate preparation are followed. (Photo courtesy of Carlisle Coatings & Waterproofing Inc.)

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Waterproofing Concrete

Tie rod holes should be thoroughly cleaned out and dampened prior to complete fill with a proper patching material.

Concrete Surface Preparation An important step toward achieving adequate bond strength is to pay careful attention to the preparation of the surfaces that are to receive the waterproofing materials. Proper waterproofing performance depends on good surface preparation. The concrete surface must not be contaminated by chemicals that can have an adverse effect on the adhesion properties of the waterproofing membrane to the concrete surface. The surfaces must be newly exposed concrete that is free of loose, weak or unsound materials. Concrete surfaces should be generally dry; however, some waterproofing membrane manufacturers allow the placement of their materials over damp concrete surfaces. The waterproofing manufacturer should be contacted for specific requirements in these cases. Care must be taken to prevent moisture from collecting at the interface between the concrete and the waterproofing membrane during curing. Prior to the application of the waterproofing membrane, testing should be completed to determine the adequacy of the surface preparation. The strength of the prepared concrete, as well as the ability of the membrane to adhere to the concrete, is two major items that must be checked prior to the project inception. The waterproofing manufacturer’s requirements and requirements of the American Concrete Institute and ASTM should be reviewed for recommended practices in these cases.

Conclusion Concrete is susceptible to moisture infiltration and waterproofing is required in sensitive and occupied areas. This can be attested by the condition of concrete roads or driveways. The success of the waterproofing system will rely on proper concrete surface preparation. All concrete surface defects must be addressed in an acceptable

manner prior to waterproofing application. As an architect, it is best to provide proper concrete surface guidelines in the initial design. This will eliminate conflict that can arise between the different trades that are typically involved in waterproofing applications. This will lead to success in one of the most difficult to design and highly litigated components of the building. AR&W

John A. D’Annunzio is President of Paragon Consultants, a construction engineering firm he founded in 1989. He is the editorial director of Architectural Roofing & Waterproofing and a technical columnist for Roofing Contractor. He has published more than 100 articles and has written four books on building exterior issues. For more information about the company, visit www.paragonroofingtech.com.

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Q Milwaukee City Hall is clad with granite, sandstone, brick, and architectural terra cotta with a slate mansard roof punctuated by gabled dormers. It was built in 1896. (Photo by Eric Oxendorf.)

Fighting FOR

CITY HALL Companies Team Up to Restore Milwaukee Landmark by Chris King

W

hen they say “You can’t fight city hall,” they aren’t talking about Mother Nature. A nd she’s been fighting Milwaukee City Hall for a long time. Originally constructed in 1896, Milwaukee City Hall was designed by H.C. Koch in the German Renaissance Revival style. A registered National Historic Landmark and a Milwaukee icon, the building is clad with granite, sandstone, brick, and architectural terra cotta. Its slate mansard roof features gabled dormers, and a large skylight in the flat portion of the main roof floods the eight-story building atrium with natural light. At the south end of the building, the masonry clock tower rises to a height of 393 feet, where it is capped by a copper-clad spire.

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Milwaukee Landmark

Moisture infiltration had been a problem since its initial construction, and by 2001 significant deterioration was evident in the structure and envelope materials. Damage included corroded steel framing, deteriorated masonry and stained interior finishes. Furthermore, large loads from the clock gables and the masonry’s own weight had caused stress cracks to open in the walls of the South Tower. Engineering firm Simpson Gumpertz & Heger Inc. (SGH) was called in to assess the damage in the spring of 2001. SGH, the historic preservation and building envelope consultants and structural engineer of record, and Engberg Anderson, the lead local architect, pored over the results of the damage reports prepared by SGH, Wiss Janney Elsner of Chicago, and others. They devised a plan to stabilize and restore the historic structure, and their team was selected by the city to repair City Hall in 2003. Over the next five years, a team of engineers, architects, roofing contractors and specialized craftsmen worked to painstakingly restore the building. The goal was to accurately replicate the damaged elements and ensure the building would remain watertight for decades to come.

The Game Plan According to Brent Gabby, Senior Principal at SGH, the project’s phases included controlled demolition and reconstruction of the South Tower masonry above the 12th floor; repairs to corroded steel truss elements; rehabilitation of deteriorated brick and terra cotta elements; restoration of the existing windows; installation of the waterproofing materials at windows, walls, dormers and gutters, and restoration of the existing slate, copper, and membrane roofs. Gabby noted there had been several attempts to remedy these problems in the past. “According to historic records with the city, the building underwent a major restoration program about every 25 years since original construction to try to remediate cracking and water infiltration,” he said. “The earliest documentation of repairs that we found was dated 1909.” SGH was able to identify the structure’s problems through interior and exterior observations, openings in exterior walls, water testing to determine leak sources, and building movements to confirm the results of the finite element analysis of the South Tower. “Using vibrating wire strain gages and thermal couples, we recorded field data for a year and downloaded this information remotely from our office in Waltham, Massachusetts, via cellular phones,” said Gabby. “In this fashion, we were able to monitor building movement and cracking daily.” Even with the detailed damage reports, team members could not be sure exactly what they would find when demolition began, according to Engberg Anderson project architects Kevin Donahue and Daniel Kabara. “We believed we had a good handle on the work, but despite all of the exploratory openings, we knew other things would be found,” Kabara said. “Given the rate of continued deterioration, by the time construction started, conditions would be worse than at the time of assessment.”

Q Industrial rope access techniques were used to inspect cracks, material deterioration and install remote sensing devices. (Photo courtesy of Simpson Gumpertz & Heger Inc.)

As the project began, the team had to envision several possible solutions to various problems depending on the actual conditions. “Because there was limited access to the building, a lot of solutions were set up as proposed solutions,” Donahue said. “We knew we’d be tweaking the solutions in the field.” Full access to the building wasn’t possible until the scaffolding was completed. The scaffolding itself was a huge task. “Pipe staging could only rise up to the 12th floor because of height restrictions,” said Gabby. “Above this level at the South Tower, pipe scaffolding was primarily supported on temporary deep girders that cantilevered beyond the exterior face of the tower at the belfry level.” The site itself posed other challenges. Milwaukee City Hall is a fully functioning governmental building that had to stay open throughout the course of the project. Tunnels and walkways protected pedestrians and kept foot traffic flowing. Sidewalks that ran above hollow vaults had to be shored up from below. The busy streets that ran alongside the building could only be closed for brief periods. Everyone involved noted that safety was the top priority. “The one thing everyone agreed on at all times on the project is that safety comes first,” Donahue said. “You have to know what’s around A R C H I T E C T U R A L

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Milwaukee Landmark

Q LEFT: At the south end of the building, the masonry and steel-framed clock tower rises to a height of 393 feet and is capped by a copperclad spire supported on steel trusses. RIGHT: This view of the Milwaukee City Hall South Tower shows the terra cotta lion heads below the clock face. (Photos by Eric Oxendorf.)

you and what’s going on, because there are no little accidents that high in the air.”

A Lot of Terra Cotta The first step after the scaffolding was set up was to document the building’s external features so it could be put back together properly. “Before we began demolition, one important thing was to remove a sample set of decorative elements so they could be reproduced,” Kabara said. The building was taken apart piece by piece. Terra cotta elements were shipped to California to be reproduced by Gladding McBean and Co. The replacements for the larger-than-life terra cotta lion heads weighed in at roughly 900 pounds each. “It was originally built in 1893 without scaffolding,” said Donahue. “It was built from the inside out. The terra cotta was built into the walls — a 2-foot-by-3foot-by-2-foot hollow section was placed in the brick and bricked in. In many of

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the repairs, we didn’t have the luxury of removing material that held it in place. You had to develop methods for securing that piece that we couldn’t predict in advance.” Shop drawings were produced to cover proposed methods of attachment, including hooks that tied into the brick and clamps that held the terra cotta in place. Some elements, like a terra cotta lintel, were pre-assembled on the ground and hoisted into place. Before that took place, the South Tower had to be shored up. “For the most part, cracking of the South Tower was due to the geometry of the tower and its own dead weight, which resulted in high-tensile stresses above flat arches and semi-circular arches,” said Gabby. To give the tower increased tensile capacity, a reinforced concrete ring beam was installed at the 13th floor. Precast concrete backup with masonry veneer was

installed in lieu of solid masonry to lighten the dead load of the large clock gables. “Rubberized asphalt peel-and-stick membrane was installed over backup masonry or concrete with lead-coated copper flashings at strategic locations throughout the walls to drain water to the exterior,” said Gabby.

Restoring the Roof Systems Ornate copper elements topping the towers were removed individually, and many had to be recreated by Heather & Little, Ltd., Markham, Ontario. The South Tower posed an additional challenge, as it sustained significant damage in 1929 when lightning struck it, causing a fire. “It was burned back to its structural steel,” Donahue said. “It was repaired, but they simplified and excluded a number of details. As a result, we knew where stuff went — we had original building

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Milwaukee Landmark

Water Management Water intrusion had taken an obvious toll on the building throughout its more than 100 years of service, and a key goal of the restoration project was to minimize such problems in the future. “From a design perspective, the biggest challenge was improving the water management characteristics of the walls by converting the mass masonry walls to cavity walls where we could and adding a backup waterproofing membrane and flashings, while still maintaining the original aesthetic,” said Brent Gabby, Senior Principal of Simpson Gumpertz & Heger Inc. (SGH). BRENT GABBY “Another challenge was coordinating shop drawings between different trades and similarly integrating different systems in the field to maintain waterproofing continuity.” “The design incorporated new metal flashings at areas such as over new relieving angles and beneath curving terra cotta at dormers,” Gabby said. “By locating new relieving angles at steps in the masonry veneer, the flashing drip edge was typically hidden in a shadow line and difficult to detect.” Built-in gutters above the 7th floor of the main building were first covered with peel-and-stick rubberized asphalt membrane, and then fully lined with lead-coated copper over rosin paper. “Thirty-two ounce copper was installed due to the relatively long distance between expansion joints (which was dictated by building geometry) and the location of existing down leaders,” Gabby said. “Other than expansion joints, all metal flashing joints (at changes in profile and between adjoining pieces of flashing) were fully riveted and soldered watertight. Expansion joints were made watertight by stripping-in the joints with EPDM membrane (flashing laps did not rely on sealant for watertightness).”

drawings — but we had to study historical photos to get all of the details right.” A mix of 24-ounce and 32-ounce copper was used on the tower. “It’s heavier than you would normally see,” said Donahue. “It’s 300 to 400 feet up, on a lakefront in the upper Midwest with snow, high winds, driving rain and hail.” “The previous roof was torn to shreds,” said Kabara. “The copper had gaping holes in it. Granted, it was some 70 years old, but it was greatly deteriorated. Over the years it had let a lot of water in.” Some of the steel beneath the copper sheathing was not only deteriorated — it had been eaten away completely. “Some of the steel was 100 percent gone,” Kabara said. “Some of the main beams supporting the structure were gone.” The copper work was expertly handled by F.J.A. Christiansen Roofing of Milwaukee. A crane could not be used, and heavy copper pieces had to be handled with care. “Workers had to carry pieces up by hand,” said Kabara. “The most dramatic one is the 36-inch sphere that was carried up a ladder by hand and put in place on the 40-foot flagpole atop the spire.” For the flat roofs, an SBS modified bitumen was chosen to replace the existing BUR and EPDM roofs, which were torn off, exposing the clay book tile under-

Q Workers survey the outside walls of the South Tower. (Photo courtesy of Simpson Gumpertz & Heger Inc.)

neath. Work on the low-slope roofs was handled by F.J.A. Christiansen and Roberts Roofing & Siding Inc. of Milwaukee, while the slate mansard roof was restored by Pennebaker Enterprises of Milwaukee. The job was completed on time and on budget, and the project has garnered some 13 local and national awards. “One of the important factors on this job was really understanding the historic methods and materials and working with them, rather than just superimposing modern materials,” said Donahue. “We relied on traditional methods of construction and careful integration of flashings

and water management. We had to develop a restoration strategy at the beginning of the project. We weren’t going to rebuild the building, but restore it.” “They say you can’t build them like you used to,” Kabara said. “But you can build them like they used to if you have the skills — or develop them. That’s what happened here. The craftsmen really took ownership of the project.” AR&W Chris King is editor of Roofing Contractor and Architectural Roofing & Waterproofing magazines. He can be reached at 248-244-6497 or [email protected]. A R C H I T E C T U R A L

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Rooftop Vegetable Gardens Provide New Opportunities in Urban Environments

by Anna Suardini, ASLA, GRP

A

s the demand for locally grown produce increases, urban communities are becoming more and more creative in finding ways to meet that demand. Urban agriculture can be as simple as windowsill herb gardens or as vast and vibrant as large community gardens that encompass entire city blocks. The acres of unused building rooftops in these areas present the perfect environment to contribute substantially to the volume of locally grown produce in urban communities.

Gary Comer Youth Center, Chicago Not only do urban rooftops provide the space, sunlight and fresh air plants need to thrive, but in especially challenged neighborhoods they also provide a safe space for community members to interact with nature. At the Gary Comer Youth Center on Chicago’s South Side, students cultivate and maintain an 8,600-squarefoot rooftop vegetable garden. The garden is part of a comprehensive “seed-to-table”

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program where participants ages 13-18 not only plant and harvest everything from cucumbers to popcorn to potatoes in the 18-24 inches of engineered lightweight soil on the roof, but they also take part in culinary classes where they learn to prepare fresh and nutritious meals with the produce they’ve grown. Under the direction of garden manager Marji Hess, the GCYC rooftop pro-

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Room to Grow

Q Low-income residents and children plant and maintain a 3,800-squarefoot vegetable garden at the Louisville Scholar House. (Photo courtesy of American Hydrotech, Inc.)

duced more than 1,000 pounds of food last year alone. Whatever produce the students don’t use themselves is sold at a farmer’s market and to several prominent restaurants all over the city. “The rooftop garden is both an oasis from urban stress and also a stepping stone to future careers,” said Hess. “The rooftop really shows the sky is the limit when youth and gardening are brought together.”

Scholar House, Louisville Rooftop vegetable gardens have great potential as educational opportunities. A similar program on a slightly smaller scale exists on the roof of the Scholar House in Louisville, Ky. The Scholar House provides housing for low-income single parents and children while the parents pursue degrees from Q The Gary Comer Youth Center on Chicago’s South Side features a rooftop vegetable garden covering 8,600 square feet. (Photo courtesy of American Hydrotech, Inc.)

local colleges and universities. Part of the adjacent child development center is an accessible rooftop where residents and children plant and maintain a 3,800-square-foot vegetable garden. “Our children have eaten many vegetables that they had not even seen before,” said Cathe Dykstra, president and chief executive officer of Family Scholar House, the parent organization of the Louisville Scholar House. “They tried them because they grew them and cooked them with their parent. Our programs are about learning new things to break the cycle of poverty. Nutrition and environmentally-friendly living are integral to the future for our families and our community.”

Garden Roof Assembly Both projects utilize A merican Hydrotech’s Garden Roof Assembly, which starts with a hot rubberized asphalt waterproofing membrane, and includes insulation, drainage /water retention components and soil. The soil is specially engineered for a lighter weight and optimum drainage, which

allows it to be installed on a roof where weight can be a concern. This creates a gardening experience almost indistinguishable from one at ground level. Unlike a container garden, this type of built up assembly allows nutrients and water to be shared across the roof and provides plenty of room both horizontally and vertically for the plants’ roots to spread and grow. Rooftop vegetable gardens allow for the distance from the source of food to the table to be measured in feet instead of miles. This increases the nutritional quality of food and provides new opportunities for an urban population that often has limited access to fresh, high-quality produce. As the local food and urban agriculture movements gain momentum, urban rooftops will become an integral part of the way we feed our cities. AR&W Anna Suardini, ASLA, GRP, is the Garden Roof Technical Sales Coordinator for American Hydrotech, Inc. She can be reached at 312-337-4998 or asuardini@ hydrotechusa.com. A R C H I T E C T U R A L

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by Mark J. Frisch, AIA, LEED AP

New FedEx Cargo Facility Has a Massive Green Roof

T

he new FedEx Cargo Facilit F ili y at O’Hare O’H Airport in Chicago is an impressive design response to the sustainable vision promoted by the City of Chicago’s O’Hare Modernization Program (OMP). The 363,320 -gross-square-foot development includes four buildings, the World Service Center (WSC)/administration building, aircraft maintenance building, vehicle maintenance building and sort building. A 300-foot pedestrian bridge connects the WSC with the sort building, which contains the material handling systems and support spaces. But what’s most interesting about project is that it features the largest continuous vegetated roof at any airport in the world, totaling 174,442 square feet. Located next to an active runway, the project would have to meet the challenging demands of an airport environment. The design team sought a roofing system that would be wind resistant and leak proof, fall under a unified warranty (covering water tight-

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Q The FedEx Cargo Facility at O’Hare Airport in Chicago features the largest continuous vegetated roof at any airport in the world. It totals 174,442 square feet. (Image courtesy of Xero Flor America, LLC.)

ness, success of plants, and overburden removal and replacement), and allow for easy identification and quick repair so that FedEx operations would never be compromised.

The green roof system chosen was a Sarnafil PVC (thermoplastic) roof membrane with XeroFlor Vegetated Mat. The waterproof membrane layer was designed for Factory Mutual (FM) 1-35 data

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Room Ro oom to Grow G

Q LEFT: This cross-section shows the components of the roofing system. BELOW: This rendering of the site shows its proximity to the runways.

Green Roof on the FedEx Cargo Facility SIZE 174,442 square feet LOCATION Chicago GREEN ROOF TYPE Extensive COMPLETED 2010 OWNER O’Hare Modernization Program, the City of Chicago TENANT FedEx ARCHITECT Solomon Cordwell Buenz (SCB) GENERAL CONTRACTOR Power Construction Company and Ujamaa Construction (a project-specific joint venture) GREEN ROOF CONSULTANT AND INSTALLATION Intrinsic Landscaping, Inc. ROOF CONTRACTOR All American Exterior Solutions GREEN ROOF MANUFACTURER Green Roof Solutions WATERPROOFING ROOF MEMBRANE Sika Sarnafl LANDSCAPE ARCHITECT Site Design Group VEGETATION MAT Xero Flor America, Xero Flor XF301 GREEN ROOF SYSTEM BASE ASSEMBLY Green Roof Solutions Terra Roof Additional information was provided by www.greenroofs.com.

sheet standards, with FM tested 1-60 adhered roofing assembly and an integrated conductive layer for electronic leak detection. The membrane is fully recyclable at the end of its life. The vegetated mat layer was rolled out for quick installation, thereby satisfying stringent technical standards specifying high early resistance to windborne debris; there could be no risk of materials blowing off the roof and onto nearby runways. Without trays, the vegetated layer was quickly fixed to restraints, providing an instantly robust layer that would grow out and around patented anchors and disks. An experienced team of green roofing and roof membrane specialists provided technical support, while innovative contractors detailed, fabricated, installed and tested the roof system. Challenging the installation included the use of the roof as a staging area during construction and the demands of Chicago’s unforgiving winters. The green roofs of the 25,000-square-foot vehicle maintenance facility and 24,000-square-foot WSC were completed in one day, and the green roof of the 300,000-square-foot sort building was finished in just 17 days. The entire green roof is comprised of 3.9 acres of cultivated pre-vegetated mat with restraint anchors and more than 2,200 cubic yards of growing media plus 3.1 miles of aluminum edge treatment. The largest continuous roof area is the

724 feet by 224 feet over the sort facility. The entire roof is estimated to have a saturated weight of 4.3 million pounds and to retain 2 million gallons of storm water annually. It also meets the OMP’s sustainability goals to reduce the urban heat island effect. Since its completion in summer 2010, the roof has withstood two severe wind events with no damage. While adding to the sustainability of one of the nation’s busiest airports, the massive green roof beautifies a large and prominent facility by providing a seasonal display of native foliage year round. AR&W Mark J. Frisch, AIA, LEED AP, is a principal at Solomon Cordwell Buenz, an architecture, interiors, and planning firm headquartered in Chicago, with offices in San Francisco and Abu Dhabi. As principal in charge of technical design, Frisch leads initiatives in innovative materials, systems and sustainability. He consults internationally on LEED certification and emerging design technologies that utilize alternative energy solutions. He is a LEAF Award winner for Best Use of Technology, and winner of the U.S. Department of Energy’s Sun Wall Design Competition. A R C H I T E C T U R A L

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WHITE ELASTOMERIC ROOF COATINGS M

by George Daisey

Understanding the Technology That Drives Innovation

ost people have heard the terms acrylic, polymer, elastomeric and ref lective. Some terms may seem obvious while others may or may not be understood at all. All polymers are not acrylic, and all acrylics are not appropriate for all applications. In terms of polymers for elastomeric reflective roof coatings, this article will focus only on acrylic polymer technologies. Acrylic polymers can be designed to be tough and hard, flexible and soft, or at various compositions in-between. Perhaps one the hardest acrylic polymer-based products would be Plexiglas™, an extremely durable polymer composition. Though most forms of Plexiglas are clear, most acrylics are mixed with other materials to create products in thousands of colors for plastics, paints, adhesives, caulks, and other functional coatings.

Acrylic Polymers The term acrylic often refers to a polymer that is made of two or more acrylic monomers. Figure 1 contains a list of some of the more common monomers used for coatings and paints. The first four monomers whose names end with “acrylate” are acrylic monomers. The last two monomers are not acrylic. It is quite common among polymer suppliers to refer to certain polymers as BA/MMA or some other acronym to describe the basic combination of monomers for that product. Though in a simplistic way it is easy to understand that blending hard monomers (high Tg) with softer monomers (low Tg) can lead

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Q Acrylic elastomeric roof coatings are liquid-applied, seamless, fully adhered membranes that are formed in situ on the roof. Some installations are coating-only, while others combine a variety of fabric designs into the coating matrix, literally creating a membrane on the roof. (Photo courtesy of Dow Roofing Systems and the Reflective Roof Coatings Institute.)

to a near infinite combination of monomers resulting in many unique products. Couple this knowledge with additional components and additives used by polymer suppliers which are proprietary and never disclosed, the variety of products that

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MONOMER

ACRONYM

Tg, °C

Methylmethacrylate

MMA

+105

Ethylacrylate

EA

-22

Butylacrylate

BA

-54

2-Ethylhexylacrylate

2-EHA

-85

Styrene

STY

+100

Vinylacetate

VA

+29

Q FIGURE 1 Common Monomers. Note: Tg is an abbreviation for Glass Transition Temperature. The term is commonly used to describe the “hardness” of an acrylic polymer.

can be produced increases significantly. Figure 2 shows a simple illustration of where many product types fall along the Tg scale. Tg — an abbreviation for Glass Transition Temperature — is a term commonly used to describe the “hardness” of an acrylic polymer. If the ratio of hard and soft monomers contains mostly the hard monomer, then the Tg of the final polymer will be higher. Conversely, if there is more of the soft monomer than hard monomer, then the Tg will be lower. Figure 3 shows a generic Tg curve. The curve illustrates that if the temperature of the polymer is colder than the reported Tg, then the polymer will be glassy and brittle. If the temperature of the polymer is above the reported Tg, then the polymer will be rubbery and elastic. Products that need to be rubbery and elastic under cold conditions will usually have very low Tg, sometimes as low as -45°C. The important thing to remember about acrylic polymers is that they can be used for a variety of applications but you need to have the proper acrylic technology for the right job. For example, acrylic polymers used for making floor polish or house paint would both make very poor choices for an elastomeric roof coating.

Acrylic Elastomeric Reflective Roof Coatings Acrylic polymers have now been specifically designed for roofing applica-

tions. Back in the 1980s and even into the 1990s, mistakes were made when house paints were applied on roofs. The results were disastrous because these house paints were much too brittle. Others tried to use caulk and sealant technology to make elastomeric roof coatings, thinking that because they are “soft” they will work. The properties needed for a roof coating far exceed just whether the coating is harder or softer. Expectedly, using caulks or adhesives as a roof coating also met with abysmal failure. Today the technical requirements for a successful roof coating are fully understood and in most cases the proper acrylic polymer is used for the proper end use. Acrylic elastomeric roof coatings are liquid-applied, seamless, fully adhered membranes that are formed in situ on the roof. These coatings are applied 6 to 8 times thicker than house paint. Typically, the thickness of exterior house paint is 3 dry mils, or 0.003 inches. For elastomeric roofing applications, the application rate is typically 18 to 20 dry mils minimum, with higher quality installations being applied at 30 dry mils or more. Some installations are coating-only; while others will combine a variety of fabric designs into the coating matrix, literally creating a membrane on the roof. Competing products known as single-ply membranes are created in a factory, and then applied to a roof. For example, products like PVC, EPDM or TPO are often supplied in

sheets 45 mils or thicker. Unlike these single-ply materials, the acrylic roof coating has no seams. Additionally, it is also fully adhered; not requiring mechanical fasteners or adhesives as do single-ply membranes.

Brightness and Reflectivity Most acrylic elastomeric roof coatings are white or near-white in color. The whiteness of the coating provides two very important features. First it reduces the temperature of the roof surface and more importantly to the membrane to which it is applied. This reduced temperature coupled with the UV blocking properties of the coating reduces the rate of degradation and deterioration of the underlying roofing membrane. Second, the white color reflects as much as 95 percent of the heat portion of the sunlight, reducing the heat transferred into the building and thus reducing the air conditioning costs for that building. For most industrial applications, white acrylic elastomeric roof coatings are the perfect choice because most of these buildings have horizontal, or flat, roofs. The high brightness and reflectivity of the coatings is ideal for reflecting the sun’s energy back into outer space. For residential applications, however, most structures have sloped roofs and the high brightness of the coating would be undesirable. For this reason, residential roof coatings are usually tinted to a A R C H I T E C T U R A L

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Elastomeric Roof Coatings

Textiles, Non-woven Fabric

Adhesive

Paper

Caulk

Industrial

Architectural Coating

Floor Polishes

Increasing Glass Transition Temperature “Soft”

“Medium”

“Hard”

Q FIGURE 2 Products and Tg. Note: Tg is an abbreviation for Glass Transition Temperature. The term is commonly used to describe the “hardness” of an acrylic polymer.

{

“The key property required of any roof coating material is durability. Acrylic technology is widely used in exterior coating applications because of its durability.”

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medium to deep tone color and are rarely elastomeric technology.

properties as needed to maintain cool roof performance.

Be Flexible

Durability Requirements

A roof is not a static structure, meaning that a roof is constantly expanding and contracting with temperature and humidity f luctuations, seismic expansion, the weight of snow and rain loads, wind uplift and even vibrations of the building. The roof coating must also tolerate resistance to foot traffic and even dropping of tools and equipment on the coating. Remember there are many types of equipment that can be located on a roof, including HVAC units, cooling towers, satellite dish antennas; ventilation and cooling ducts, and so on. Flexibility does not just mean being stretchy. Bubble gum is stretchy but quite inappropriate as a roof coating. The point is that other elastomeric type products might be flexible, but totally inappropriate for roofing applications. Caulks, sealants, adhesives, and even elastomeric wall coatings would be completely inappropriate for use as a roof coating. This is because these products are not designed to have the resistance to standing water or impact, and would not be able to retain solar reflectivity

The key property required of any roof coating material is durability. Acrylic technology is widely used in exterior coating applications because of its durability. Durability implies resistance to the effects of ultraviolet radiation (UV) degradation from the sun. Acrylic polymers are transparent to UV which means they do not absorb this most destructive part of the sun’s radiation. The white pigments in an elastomeric coating reflect a majority of the visible and infrared wavelengths of sunlight but they do absorb some of the UV component of sunlight, which is about five percent of that spectrum. Fortunately, the acrylic polymer is not contributing to the absorption of any of the UV radiation. This gives an acrylic elastomeric roof coating a stark advantage over other polymers. For example, asphalt absorbs some of the radiation, and the asphalt begins to vibrate, and break up into smaller pieces. This is the degradation that is associated with the harmful effects of sunlight. This can be seen readily in aged asphalt roofing. Usually within six months, there’s a brown chalky residue on the surface of

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Elastomeric Roof Coatings

an asphalt-based coating. This is the result of ultraviolet degradation from the sun. When that same acrylic polymer is formulated into a roof coating and the UV transmission is measured, there is no transmission. This is because the pigments are either reflecting the sun’s energy or absorbing it, effectively protecting the roof substrate beneath.

Reduced Energy Costs Reflectivity and dirt pickup resistance are key properties for an elastomeric roof coating. Many utilities now offer energy rebates for installations of reflective roof systems. The longer the coating stays white, the longer the reflectivity is maximized. An infrared thermometer is an easy way to measure the surface temperature of a roof. For scientific experiments, sophisticated IR thermometers are used; but for showing simple temperature comparisons between a white and dark roof, any inexpensive IR thermometer is a great way to quickly demonstrate the cooling effects of a white reflective roof coating. Figure 4 shows the surface temperature measured as a function of the time of day of a black roofing shingle versus the same type of shingle coated with a white acrylic elastomeric roof coating. The vertical axis is temperature; the horizontal axis is the time of day. The surface temperature was measured using the infrared thermometer. The maximum air temperature reached during this day was 90°F. The black asphalt shingle reached a maximum temperature of 160°F. This same black asphalt shingle coated with 100 percent acrylic elastomeric coating never reached 100°F. This shows the benefits of reflectivity as the white elastomeric acrylic coating protects the asphalt roofing material and keeps it cooler. But the story is not over; there is a second benefit here. Consider a warm August afternoon where sudden, quick moving thunder showers are the norm. It’s 3:30 in the afternoon and that black asphalt shingle has a surface temperature of 160°F, then a thunder shower occurs. The temperature of the shingle drops from 160° to 80°F in 15 minutes. The white coating’s temperature drops from 90°F to 80°F in 15 minutes. The black shingle experiences considerably more thermal shock; with an 80°F temperature drop versus a 10°F drop. The black single is undergoing a lot more stress, a lot more strain, more expansion and contraction, as a result of these temperature fluctuations. The thermal stress will shorten the life of a black roof.

that releases water to quench the flames. One common ingredient proven for decades is Aluminum Trihydrate (ATH). Formulating ATH into an ERC is very easy and cost competitive versus other technologies. Second, additives that release halogens work like a halogen fire extinguisher, releasing components that smother the fire. There are many materials based on halogenated chemistries that can be formulated into an ERC to deliver this performance. Lastly, additives can be used to create a char layer as the coating is burned. These coatings are commonly referred to as intumescent coatings. The char layer is created as the coating burns; the coating literally expands, creating a charred, physical barrier to the flame.

Limitations of Acrylic Elastomeric Roof Coatings There are limitations to an ERC. These coatings can provide some restoration to an aged roof. However, if the roof is too badly deteriorated or the deck is rotted or badly corroded, coating will not return the roof to a useful service life. An ERC is meant to extend the life of a roof, not repair it. Acrylic ERC cannot be applied in the rain or when precipitation is imminent. Acrylic ERCs are applied at rates 10 times thicker than house paint and it will take longer to dry. If the relative humidity is extremely high, say over 90 percent, it will take an extremely long time to dry. New technologies are

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Fire Retardancy Another benefit of acrylic elastomeric roof coatings is in the area of fire retardancy. Many roofing systems require an Underwriter’s Laboratory class A rating which can be confirmed according to a standard specification UL790. Acrylic Elastomeric Roof Coatings can be formulated with fire retardant pigments to reduce the burning effects on the roofing system. There are three basic ways to stop flame propagation across or into a roof. First, the ERC can contain a component A R C H I T E C T U R A L

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Elastomeric Roof Coatings

Effect of Temperature on Resistance to Deformation

Stiffness

Glassy, brittle

Glass Temperature, Tg

Effect of crosslinking Rubbery, elastic

Temperature Q FIGURE 3 Generic Tg Curve

Conclusions

Effect of White Roof Mastic on Surface Temperature 150º 140º

Black Uncoated Shingles

Temp (ºF)

130º 120º

White Mastic Coated Shingles

110º 100º 90º 80º

Air Temp.

70º 60º 8:30

9:30

10:30

11:30

12:30 Time

1:30

2:30

3:30

4:30

Q FIGURE 4 The Effect of White Roof Mastic on Surface Temperatures

emerging which give significantly faster resistance to rain after the coating is applied; but acrylic ERCs are waterborne, so application during rain is not possible. No ERC should be applied in the rain or over wet conditions. Acrylic ERC coatings should not be applied when it is extremely cold. Water freezes, so there are limitations as to the time of year when you can apply the coating. The contractor needs to be conscientious about what the overnight temperature is. It might be warm during the day. But if the evening temperature

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may be dirty or may have a powdery degraded roofing material on it or a new roof membrane may have mica or talc dusting on the surface. These powdery materials prevent the roof coating from achieving acceptable adhesion to the roof membrane substrate. Simply stated, the roof must be properly cleaned, usually with detergent and a pressure washer, to achieve a clean substrate suitable for coating. Just as house paint would not be applied to chipped or peeling surfaces or mold spores, an elastomeric roof coating would not be applied to a substrate that wasn’t mechanically sound and free of debris, dirt, and powdery degraded roof substrate.

is going to drop to the mid-20s, there may be a serious problem with freezing of the coating. Further, it is not just the air temperature, but the temperature of the surface to be coated that’s important. Commonly, acrylic ERCs are applied when air temperatures are at a minimum of 50°F and rising. Another important consideration for the successful application of these elastomeric roof coatings is that the adhesion of the coating is only as good as how mechanically sound the substrate is. An aged roof membrane surface

• Acrylic coatings provide extended durability. They can be applied over most types of roofing systems and they will dramatically enhance the life of those roofs. They can be applied initially, to a new roof, and they can be applied somewhere later during the life of the existing roof. • They reduce the energy costs. A white acrylic roof coating applied over a smooth surface built-up roof reduces the energy costs, saves money, and also extends the life of that roof. • Acrylic coatings can lower the roof life-cycle costs by making the roof last longer, and can extend the date that the roof will be replaced. • From an aesthetic standpoint, these acrylic coatings can be supplied as white for ref lectivity, and earth tone colors to compliment the building architecture. AR&W George Daisey is a Manager of Sales and Technical Service in the Dow Constr uction Chemicals business unit at The Dow Chemical Company (www.dow.com). The Dow Chemical Company is a member of the Reflective Roof Coatings Institute (RRCI), and the author is currently a member of the RRCI Technical Committee. For more information about the RCCI, visit www.therrci.org.

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FORM &

by Kate Gawlik

“I

Scalloped Metal Tile Roof Ties Together the Elements of the Station at Potomac Yard

FUNCTION

t is the pervading law of all things organic and inorganic, of all things physical and metaphysical, of all things human and all things superhuman, of all true manifestations of the head, of the heart, of the soul, that the life is recognizable in its expression, that form ever follows function. This is the law.” So said renowned architect Louis Sullivan. From his mind, a new age of architecture was born — one that still exists today, in which a building’s function must dictate its form. The Station at Potomac Yard, Alexandria, Va., tested Sullivan’s theory because of its unique functions. The project is the first known building in the United States that combines a fire station, affordable housing and retail.

“Accommodating such different functions engendered many challenges, starting with schematic design and continuing up to the point of occupancy,” said John Rust, AIA, of Rust Orling Architecture, Alexandria. Rust Orling Architecture, which served as associate architect of the project, focused on the exterior design and was

Q ABOVE: The 169,000-square-foot structure occupies an entire city block and cost approximately $29 million to build. RIGHT: The south elevation, shown in this rendering, is the residential entry. It features a masonry gable, a two-story gallery and a series of corbelled arches. (Photo and Graphic courtesy of Rust Orling Architecture.)

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Form & Function

Q LEFT: The scalloped metal tile roof from ATAS International ties the various elements of the building together. RIGHT: The five bays of the fire station are seen on the east elevation. A residential terrace is located above the fire bays. (Photos courtesy of Rust Orling Architecture.)

joined by a team of experts to create this innovative mixed-use structure. Others involved included: developer, Alexandria-based Potomac Yard Development LLC (PYD), a joint venture of national home builders Pulte and Centex; the city of Alexandria; architect of record, LeMay Erickson Wilcox Architects, Reston, Va.; general contractor, Whiting Turner Contracting Co., Baltimore; roofing contractor, Prospect Waterproofing Co., Sterling, Va.; and roofing distributor, Bradco Supply Corp., Lorton, Va. In 2004, PYD and its architectural team began the design phase of a mixeduse space on a former rail yard. Initial plans posed a major problem for the city, however — the key question was how to get emergency equipment to the residential and retail spaces within the optimal response time. This problem was resolved by adding a bit more land to the initial design and incorporating the fire station into the building. “Ultimately PYD provided just over 1 acre of land, as well as $ 6.6 million, toward the cost of developing and building Station 209,” explained Jeremy McPike, PMP, LEED AP, the deputy director of the department of

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general services for the city of Alexandria. “The city chose to maximize the donation of land by leveraging air rights above the station for affordable housing. Through the community process, a component of workforce rental housing was also added.” With the addition of the fire station and varied residential units, the team had many different issues to address. This was the first fire station to be built in Alexandria in 30 years, and the designers wanted the station to make a statement. Rust added that the building scale and materials identify it as an important civic building. Also, they wanted each unit — retail, residential and fire station — to have its own identity within a larger design scheme. In addition, doing all of this in a sustainable fashion was important. An energy-efficient element that ties everything together is the roof — a metal roof from ATAS International Inc., Allentown, Pa. “The design team selected ScanRoof, a scalloped metal tile system,” explained Jim Bush, vice president of sales for ATAS. “The roof obviously adds to the aesthetics of the building — joining the many elements with a unifying architectural style — but it also contributes to the sustainability of the structure.”

The Elements Overall, the project occupies an entire street block. It is about 169,000 square feet with two levels of underground parking occupying 62,000 square feet; a five-bay firehouse that is 24,800 square

feet; 1,400 square feet of retail space; and four floors of residential living space at 80,607 square feet. From the bottom up, the building has: two levels of underground parking; a first floor that includes the fire station, community room and retail space; and four stories of apartments above. The second floor includes a residential terrace over the fire bays. Construction took place from December 2007 to August 2009 with a cost of approximately $29 million. The design team didn’t want passersby — or occupants — to scratch their heads wondering how to access the different elements, so they came up with a way to designate them. “The primary design challenge was to give each function an identity that would provide clarity for disparate groups of occupants,” Rust said. “The solution was to place the entrance to each major activity on a different façade. This allowed building elements and architectural details to be appropriate to the scale of the various functions.” The east elevation is designated as the fire station entrance, obviously identifiable by the five-bay entrance. The south elevation is the residential entry, which is identified by a masonry gable, a twostory gallery and a series of corbelled arches. The four-story residential component includes 44 long-term affordable rental units, as well as 20 apartments with rents affordable for city workers. The retail spaces can be accessed from the southwest corner. The retail sections design is different than other aspects of the building, in order to further dis-

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Form & Function

tinguish the different spaces. Also, the design team wanted the retail space to have a historic look, suggesting that the building had expanded and evolved from its original retail space. With different entrances, distinctive looks and unique designs, how is the Station held together as a unified force? The roof, of course. A ScanRoof (SCP163) in Mission Red was selected from ATAS. The roof is a 24-gauge steel scalloped tile system that has a Spanish flair. “A tile roof is appropriate to the historic and architectural style being referenced,” Rust noted. ScanRoof is installed horizontally, from eave to ridge, on an open frame system or solid deck. The panels are structural, practical and economically efficient for any project. With their weather-resistance characteristics and wind-uplift ratings, the panels are ideal to stand up against Mother Nature’s storms. In addition, the ScanRoof system design creates an air space between the metal panel and roof deck, making an air cavity that aids in both heating and cooling reduction.

bills. The air cavity also contributes to energy conservation.” W hen developing the Station, it seems that all involved got it right. According to McPike, residential units are 100 percent occupied, and retail space leases began in late 2010. “There has been tremendous interest,” he added. “Many visitors from other states and even internationally

would like to replicate the project. The residents and the fire service are very pleased.” And it is no surprise that they would be pleased in a building where form so logically follows function. AR&W Kate Gawlik is a marketing consultant for ATAS International Inc., Allentown, Pa. She is located in Woodridge, Ill.

Full Capacity It was important to the city of Alexandria to make this new building sustainable. This was accomplished by setting two goals: for the fire station to obtain LEED Silver certification and the residential portion to receive EarthCraft Certification. The EarthCraft standard has been met, and LEED recognition is still pending. McPike noted that the energy efficiency of the residential units has been studied, and one-bedroom units are reported to save more than $100 per month on utilities because of the sustainable items incorporated into the units. “The ATAS roof contributes to the sustainability of the Station in many ways,” Bush said. “First, the roof is made with recycled content and is recyclable at the end of its useful life. Next, the roof has a cool coating that raises the solar ref lective index. This ultimately keeps the inside of the building cooler in the summer, translating into less energy usage and lower utility

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{ LegallySpeaking by Richard D. Alaniz

The FMLA: It’s Not Just For Pregnancies Anymore

A

recent survey conducted by allbusiness.com determined that the average cost to defend a Family Medical Leave Act (FMLA) lawsuit is $80,000, even if you win. In 2008, Chase bank didn’t win and was ordered to pay almost $8 million for violations under the FMLA. Although many people immediately think of pregnancies when someone mentions FMLA, it is actually a resource for employees impacted by any number of health conditions. The FMLA is a federal law requiring employers to give covered employees up to 12 weeks of unpaid leave for serious health conditions as well as several other employee needs such as the birth or adoption of a child. The law applies to all public sector employers and any private sector employer with at least 50 employees. A covered employee is any employee with at least 12 months and 1,250 hours of service to the employer. In short, if your company has at least 50 employees and you have operated for at least a year, you need to understand the FMLA better than Chase bank did.

Six Degrees of Serious ition Health Condition An employee is entitled to FMLA leave for any “serious health condition.” And the employeee can take leave for either her their own serious health condition dition or that of a close family member. So o what is a “serious health condition”? There are actually six definitions and d an employee only needs one. 1. An illness, injury, njury, impairment, or al condition that involves physical or mental inpatient care at a hospital, hospice or residential care facility. eatment by a health care pro2. Continuing treatment d of incapacity related to pregnanvider for any period cy or prenatal care. 3. Continuing treatment eatment by a health care provider apacity that is permanent or longfor a period of incapacity ition for which treatment may not term due to a condition be effective. eatment by a health care provider for 4. Continuing treatment ceive multiple treatments for restorany absences to receive

32

ative surgery or for a condition that would result in at least three days of incapacity if untreated. 5. Continuing treatment by a health care provider for a period of incapacity lasting more than three full consecutive calendar days. 6. Continuing treatment by a health care provider for any period of incapacity or treatment for chronic serious health conditions over an extended period of time. If you’re thinking, “Wow, that’s a lot of different things” — you’re absolutely right. It’s because FMLA extends to so many different medical conditions that it’s easy to mistakenly deny an employee leave they are entitled to. And that’s a lawsuit. Definitions 5 and 6 are particularly vulnerable to employee abuse and have consistently been a thorn in the side of employers. In a minor victory for employers, the Department of Labor did add some new restrictions to the definitions. Definition 5 now requires that the employee em must make two separate visits to the doctor wit within 30 days of the incapacity. The first visit must be within 7 days of the incapac incapacity. Alternatively, the employee employe may receive one treatment within 7 days of the i nc a p a c i t y a nd u then undergo a regimen of treatment. Definition 6 now vis to a health care requires at least two visits provider per year befo before the treatment is considered periodic.

New Coverag Coverage For Military Families The realities of extended military deployments for our men and wom women in uniform have led Congress to create two new categories of them. The first is for coverage designed to help the Qualifying Exigencies related tto a call to active duty. The second is a Military Caregiver C category intended to allow employees to care for a family member who was injured or who aggravated an injury while on active duty. The Qualifying Exigencies category catego gives employees 12 weeks of unpaid leave to deal with circumstances arisduty or call to active ing out of a family member’s active d

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duty status. The Department of Labor has identified eight circumstances that constitute a qualifying exigency: 1. Anytime the call to active duty status is seven days or less (short notice deployment). 2. To attend military events and official activities. 3. To attend to childcare and school activities. 4. To make financial or legal arrangements. 5. To attend non-health care related counseling. 6. An employee is entitled to five days of FMLA leave to spend with a family member on shortterm rest leave. 7. To attend post-deployment activities such as ceremonies for up to 90 days after active duty ends. 8. To attend additional activities not listed but agreed to by the employer. The Military Caregiver category allows an employee to take up to 26 weeks in a 12-month period (the longest period afforded any category under FMLA law) to care for a spouse, son, daughter, parent, or next of kin recovering from a serious illness or injury sustained while serving on active duty. Military caregiver leave may be combined with other types of FMLA leave, but the total FMLA leave cannot exceed 26 weeks in any 12-month period.

Other Changes to the FMLA

the DOL interpretation applies to non-traditional families, including same sex partners. In what must have been an accident, the DOL made some changes that actually help employers. The biggest is a new requirement that employees provide medical certification of their serious health condition. This comes with several caveats. Employers should use DOL form WH-380 E/F to ensure their request for certification only requests permissible information. Once completed, the form may only be given to the employer’s human resources professional, a leave administrator, or a management official. But under no circumstances may the form be given to an employee’s direct supervisor. If an employer is unsatisfied with the certification provided by the employee, it must notify the employee in writing of what portions are incomplete or insufficient and give the employee seven calendar days to cure the deficiency. Employers are also now permitted to request a new medical certification each leave year for conditions lasting longer than one year. Another win for employers was new regulations requiring employees to notify employers they are taking FMLA leave using the employer’s usual and customary call-in procedures for reporting absences, absent unusual circumstances. Under the old law, employees could be absent for two full days before they were required to notify their employer.

}

“If you don’t already have one, designate a trusted manager as the FMLA decision-maker and record-keeper, preferably one familiar with your policies.”

Congress made substantial changes to the FMLA in 2009. Under the old law, many FMLA violations were subject to a “categorical” penalty which awarded employees 12 more weeks of FMLA leave for any employer violation. Employers pointed out that at least some technical violations resulted in only a minimal impact on the employee and should not warrant a full 12 more weeks of leave. And the Department of Labor actually listened. Under the new FMLA, the categorical penalty has been removed and now courts assess the impact of the specific violation before imposing any penalties. Another change was barely a change at all, but it is helpful for employers. Employers have always been able to require employees to use their paid time off — sick time, comp time, vacation time, etc. — as part of their FMLA leave. The courts clarified that all paid time off is now treated the same for FMLA purposes. As recently as June 2010, the Department of Labor (DOL) clarified the definition of “son and daughter” under the FMLA to include employees who have no biological or legal relationship to the child, but assume the role of caring for them. Thus,

Things To Do Now

If you don’t already have one, designate a trusted manager as the FMLA decision-maker and record-keeper, preferably one familiar with your policies. Pick a manager who is not a direct supervisor of any employees who might ask for FMLA leave, if at all possible. Have that manager visit the Department of Labor website and familiarize themselves with the new rules of the FMLA. Last, update the company FMLA compliance policies. The new regulations give employers new rights. Make the most of them. AR&W

Richard D. Alaniz is senior partner at Alaniz and Schraeder, a national labor and employment firm based in Houston. He has been at the forefront of labor and employment law for more than 30 years, including stints with the U.S. Department of Labor and the National Labor Relations Board. He can be reached at 281-833-2200 or [email protected]. A R C H I T E C T U R A L

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Register Now For The All New 2011 ARW Webinar Series! February 22 – Roofing and Waterproofing Codes March 15 – How to Specify Underlayments April 19 – Designing Waterproofing Systems For Basement Conversions From Crawl Spaces Plus many more to come throughout the year! Attention Architects!

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Where Are You Reading This?

I

’m a print guy. I love the printed word. I love the feel of paper in my hand. I like nothing more that to curl up with a good book — on the couch, at the beach, even in the bathtub, although I can’t think of the last time I’ve taken a bath. When I’m at lunch by myself, there’s a magazine or a newspaper on the table next to me. When I’m on a plane, I’ve got articles and trade magazines and a novel in my briefcase next to my laptop. If I’m going down the hall to the … well, let’s just say my last name is King, and there are a lot of jokes at my house about reading in the “throne room.” However, as we put together this print issue of Architectural Roofing & Waterproofing, I’m reminded that the majority of the reading I do now is digital, not print. I don’t know when I passed the tipping point, but I have. I read articles on my computer at work, on my laptop at home, and on my iPhone just about anywhere. The article I pull out of my briefcase at lunch or on a plane is just as likely to be something I printed off the Internet as a glossy trade publication or daily newspaper. In fact, in my home town the daily newspaper is only available online. The actual hard copy is only delivered three days a week; the rest of the time, it’s on my laptop or iPhone. And that’s how it is with Architectural Roofing & Waterproofing. I love putting together the print volumes of ARW, but I realize they are just a small piece of our content. We’re much more than a magazine — so much so that I’ve stopped thinking of it as one. It’s a portal to information. Our web-

site is where the majority of our readers find our articles. Our e-newsletters and webinars reach far more people than our printed pages do, and more people read our digital editions than our print ones. That said, I hope we never stop producing the paper version. I love the feel of the printed page in my hand. But somewhere along the line I realized that I’m not just a print guy. I’m a content guy. I love the written word, on paper or on a computer screen. In a way, I think of print much as I think of a classic car — something I love and appreciate, but not something I drive to work in every day. It’s a digital age, but there will always be a place for print in my life. After all, there are some places an iPhone just won’t cut it, like the bathtub. Where are you reading this editor’s note? Is it in print or online? Wherever you are, we hope you keep finding ARW on your laptop, your smart phone or your tablet. We hope you log in to our webinars for technical training and continuing education credits. And we hope you keep an eye out for our next print edition at industry trade shows and events. If you’d like me to send you a copy of our next print edition, please drop me a line or shoot me an e-mail at [email protected] and I’ll make sure we send one out to you. It might come in handy. After all, you don’t want to get ketchup on your iPhone.

Chris King, Editor [email protected]

A R C H I T E C T U R A L

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Editor'sNote