Denver, Colorado (10/16/2003) --- Seattle-Tacoma International Airport's expansion presented a number of challenges for the roofing contractors, Wayne's Roofing, Inc. of Sumner, Wash. including unique architectural roofing details, multiple Johns Manville UltraGard™ roof system assemblies and aesthetic requirements of the building designers. The south terminal expansion project, which is nearing completion, is the most recent phase of a 10-year expansion project, which consists of multiple roof levels that tie into existing structures. Coordination with all of the trades was critical, as was working within the constraints of the rainy Seattle weather. With good planning and cooperation, the roofing project went smoothly.
Wayne's Roofing, Inc. was selected to perform the roofing portion of the project for their ability to perform complex projects and provide competitive pricing. The nearly $2 million roofing contract lasted approximately 2-years with application closely following the construction schedule.
"Clark Construction was instrumental in properly executing all of the trades," said Jonathan Gwinner, estimator and project manager, Wayne's Roofing, Inc. "Clark's team was easy to work with, very cooperative and did an excellent job."
At the design phase, roofing consultant Rick Wright of J/Randall & Associates worked closely with NBBJ Design to select the membrane and design the roofing system. Johns Manville, the membrane manufacturer, was included in the design meetings as well. In addition, Clark met several times with Wayne's Roofing, Inc. to iron out any details before the project started.
Performance and appearance were key components in the selection of the roofing membrane. Brian Rich, an architect with NBBJ said that initially three different systems-EPDM, TPO and PVC were considered.
"A PVC membrane was selected because the client had excellent results with PVC on other parts of the airport and it met the cost parameters of the project," Rich said. "In addition, the white PVC roof minimized heat gain and cooling loads within the buildings. PVC also is easily maintained and its flexibility accommodated the complex cricket/valley geometry of the roof, providing a continuous visual appearance."
The project consists of a south concourse, an office tower and the south hall. Of the three, the concourse was the most challenging due to its 2,400-foot length and the 'butterfly roof' design. On the steel deck of the concourse roof, Wayne's Roofing, Inc. laid ½ inch of thermal barrier board and 2.6 inches of JM polyisocyanurate PSI 25 roof insulation. In order to drain the V-section of the concourse roof, a complex system of JM tapered crickets were used between roof drains. In addition, the height of the parapet at the building ends was tapered from 10 inches at the valley to 2 inches at the high points of the eaves in order to achieve the tapered butterfly shape appearance. The JM UltraGard® SR-60 PVC membrane was then mechanically fastened with JM High Load Fasteners and Plates to comply with the FM 1-120 wind uplift pattern.
Wayne's Roofing, Inc. recommended using a JM DynaWeld™ Base vapor barrier over the concrete deck of the office building, in lieu of the originally specified polyethylene sheet. This component was torch-applied to protect against latent moisture in the concrete deck, as well as providing a temporary roof until other trades could complete their work. Over the vapor barrier, Wayne's Roofing, Inc. adhered tapered polyisocyanurate PSI 25 insulation. The UltraGard SR60 PVC membrane was fully adhered over the insulation. On the 20,000 square-foot observation deck of the office building, concrete pavers and a wood walking deck were used. In addition, planters were placed along one side of the roof deck to provide aesthetic appeal and a continuation of the guardrail system.
The roof on the south hall had a complex curved wood nailer edge detail, which required unique multiple layers of custom milled and treated lumber. Again, polyisocyanurate PSI 25 insulation was used with an UltraGard SR60 PVC membrane as well as a special detail to tie the new roofs on the project to the existing roofs, particularly at the expansion joints.
According to Wright, there were many unique details throughout the project, which is one reason he recommended using single ply. He said that NBBJ's design was aesthetically pleasing but definitely presented some detail challenges, which required design changes throughout the project.
Gwinner said that the Johns Manville sales and technical staff were very helpful and performed progress inspections throughout the project, which were documented by Wright.
In addition to the complex details of the roofing system and design, Wayne's Roofing, Inc. also had to work around the Seattle weather, which included extended workdays and weekends after rainy weather. Despite the weather, Wayne's Roofing, Inc. was able to keep up with the project's scheduling requirements. The company also was able to accommodate increased work-site security after the September 11 tragedy. Gwinner said, "My first onsite coordination meeting was on September 13, 2-days after the tragedy. The jobsite was completely shut down for 3-days."
"It's a commitment from the sub-contractors to do what they say they are going to do," said Granger Stuck, head project executive for Clark. "Wayne's Roofing lived up to that commitment. They told us what they needed and we gave it to them. It was a win-win situation."
In addition to Brian Rich, who worked through issues related to the roofing system during construction, the NBBJ design team consisted of Gary Harris who detailed the roof and Ed Storer who wrote the specification. For Clark Construction Group, Inc., Wayne Moloznik was the senior superintendent, Marty McMahon was senior project manager, and Linda Dulik was the project manager for the roofing portion of the project. For Wayne's Roofing, Inc. Jonathan Gwinner was the project manager, Dan Johnson was the operations manager and Don Guthrie, the president of Wayne's Roofing, Inc. oversaw the technical and contractor administration of the project. David Wetherbee was the foreman and superintendent. He was instrumental in following up on all of the daily issues ensuring the project performed to high quality standards and completed according to schedule. The roof crew, members of Roofers Local #153 of Tacoma, was able to quickly adapt to ever changing aspects of the project.
Wayne's Roofing, Inc. has since been awarded two additional projects at the Seattle (SeaTac) Airport consisting of the central terminal expansion package 2 and the 2003 south satellite roof replacement Both projects will have JM E'NRG'Y 3Ô roof insulation and UltraGard SR-60 membrane fully adhered. When all three projects are completed JM will have more than 460,000 square feet of UltraGard PVC roof system installed.
Wayne's Roofing, Inc. is one of the top full-service roofing contractors in the state of Washington, serving both private and commercial sectors. They are Summit Club members of the Johns Manville Peak AdvantageÔ program, a distinction that only 10 percent of Johns Manville Peak Advantage members achieve. They employ in excess of 80 people and install all types of roofing systems including built-up, modified and single ply. In 1996 Wayne's Roofing, inc. started a Professional Roofing Inspections Maintenance Evaluation (PRIME) program to maintain roofs. The business currently has more than three million square feet of roofing it maintains in the greater Puget Sound area. For more information about Wayne's Roofing visit http://www.waynesroofing.com/.
NBBJ is the second largest architectural firm in the United States, third largest in the world, with five offices in the U.S. as well as an office in London and Beijing. NBBJ has designed some of the world's top performing places, including the expansion of Sea-Tac International Airport, world headquarters for Reebok, Starbucks, and Telenor, and new stadiums for the Seattle Mariners, Cincinnati Bengals and the Milwaukee Brewers. NBBJ also is the world leader in healthcare design, with work for Swedish Medical Center, the Cleveland Clinic and Battelle Memorial Institute. Additional information can be found at http://www.nbbj.com/.
Johns Manville, a Berkshire Hathaway company, is a leading manufacturer and marketer of premium-quality building and specialty products. In business since 1858, the Denver-based company has sales in excess of $2 billion and holds leadership positions in all of the key markets that it serves. Johns Manville employs approximately 9,000 people and operates 43 manufacturing facilities in North America, Europe and China. Additional information can be found at www.jm.com.
