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Tuesday, May 20, 2008

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Is one profile enough for your business

by Jim Austin
Whoever first said, “You have to spend money to make money,” probably had plenty of it to start with. It’s easy to talk big when you’re sitting on a fat wallet.
There’s a difference between spending money and investing money. Investments should be the result of extensive research and plenty of thought, especially when it comes to running a successful business. For those roofing contractors who have made the financial commitment to purchase a roof panel roll former, there are plenty of factors to wade through before writing out that check.
A major decision revolves around purchasing a single-profile machine or a multi-profile machine. There are manufacturers who make only single-profile roll formers and some who make only multi-profile machines. Many offer both.
For those contractors who may still have questions, Mike Gorski, senior roll former technician at Englert, says the key is establishing what the machine will be used for.
“If they’re just starting out and they’re going to do residential, then they probably want a single-profile machine,” he says. “Residential is the easiest market to get started in. If they’re going to get into commercial, then they probably want to go with a multi-profile machine. A lot of times, they start with a single-profile machine and come back and buy the bigger machine.”
Gorski says the size of the investment makes a difference, too. “Everyone wants to get the most for their money,” he says. “A multi-profile machine allows you to add tooling later. If they go with a single-profile machine and want another profile, they have to buy all new hydraulics, framing, a whole new machine. Then they’ve got to worry about having a place to store a second machine.”
Englert keeps all nine of its tooling sets in stock, so any are ready to be shipped when someone orders it. A multi-profile machine allows an Englert customer to use any or all of the profiles in that machine.
Owning a multi-profile machine means knowing more than just how to run and maintain it. Contractors have to be able to change toolings to run different profiles. That can be intimidating. “We get asked a lot, ‘Do you need a masters in engineering?’” Gorski says. “We’ve tried to make it as easy as possible with color coding, by numbering the units, and requiring the least possible number of bolts you have to unscrew and screw back in.”
Gorski says Englert’s training will provide a contractor the ability to complete a changeover alone and in an hour. He says some machines will take two workers up to three hours.
Gorski says Englert’s training program is hands-on. “We don’t just send you the box and a manual and wish you luck,” he says. “We make sure someone takes you through a changeover step by step, letting you get your hands in the machine, teaching you the language. That way, if you ever have a problem down the road, we may be able to talk you through it over the phone.” Gorski says all Englert distribution centers have someone on staff to handle training and field troubleshooting. “If we don’t keep those machines running, we don’t sell coil,” he says. “We back up our machines and our material 100 percent.”
An evolving trend among Englert customers is more foresight: contractors are looking to the future when they purchase a machine. “Instead of purchasing the single-profile machine, they’re buying the multi-profile machine with the tooling for one profile,” says Kevin Corcoran, Englert’s vice president of business development. “They start out with the basic nail-strip profile. Their crews can handle it because they’ve been installing 5-v panels or ag panels. They see this as a way to grow their business. Eventually, if they want to explore more business opportunities, they can purchase another set or two.”
New Tech Machinery roof panel machines all are capable of running more than one profile. “It comes down to a philosophy,” says Roger Geer of New Tech. “Our goal has always been to manufacture a machine that was not too big, one that was truly portable, and one that was flexible enough to allow our customers to run more than one profile.”
He estimates that 75 percent of New Tech customers start with at least two profiles and that very few buy one and don’t come back for a second or third. Some are intimidated by the notion of changeovers, but Geer says New Tech’s training is very thorough. “Almost everybody who buys a machine from us spends a day or two with (New Tech trainer) Ron Schell,” he says. “He takes them through the entire machine and simplifies it.”
Geer says that approximately 80 percent of the toolings they sell between Denver and the east coast are for the 1-3/4 inch snap-lock profile. New Tech keeps all toolings in stock, ready to be sent out upon request. “We hang out hats on delivery,” Geer says.
Knudson Manufacturing offers multiple-profile machines for those who want flexibility as well as single-profile machines for contractors who know they are going to install a specific profile. Knudson’s VP21-M Varipan can run eight profiles — 1-inch flush panel, 1-inch nail strip, 1-inch snap-lock, 1-inch standing seam, 1-1/2-inch nail strip, 1-1/2-inch snap-lock, 1-1/2-inch standing seam, and a U profile. A contractor can ask for any or all of the tooling for those profiles. The machine can grow with the business.
“It depends on what the contractor is trying to accomplish and where he’s trying to take his business,” says Pat Flood of Knudson. “Is he trying to grow the business? Most customers show up with a reasonable idea of what they want. With a Varipan, you have the flexibility to bid a job even if you don’t have the tooling to do it. If you get the job, you can order the tooling. If you don’t get the bid, you’re not stuck with the tooling.”
With any new machine, there is a something new to learn and Flood says it’s important for contractors to learn all they can about their equipment. “That’s one of the advantages I’ll concede to a single-profile machine,” he says. “The learning curve is shorter. With multi-profile machines, there’s more to learn, changeovers, new setups.”
Knudson also offers several single-profile machines. “Sometimes a guy will get a good reputation for running a particular panel and it becomes his favorite profile,” Flood says. “He will seek out that kind of work and that work will seek him out.”
Flood says if a contractor opts to have a couple single-profile machines instead of one multi-profile machine, he can be running panels in two places at once. He also runs the risk of having an idle machine. “Not everyone can afford to have a machine sitting in a warehouse for weeks at a time,” Flood says. “Running single-profile machines is one way to grow. It requires a smaller initial investment, but will require sizable investments with the purchase of additional single-profile machines later on,” Flood says. “That’s one way to grow a business, adding to the stable.”
Flood says contractors who operate a multiple-profile machine can use it as a marketing tool, showing their versatility.
Texas-based Berridge Manufacturing offers only single-profile roll formers, or “dedicated-profile” roll formers as they’re known at Berridge. “One reason roofing contractors prefer to purchase several single-profile portable roll formers is to be able to produce panels for more than one project simultaneously during peak demand without having to go through the sometimes lengthy and tedious process of changing tooling and making adjustments,” says David Doyle, Berridge’s vice president of marketing. “Roofing contractors who purchase a Berridge dedicated-profile roll former do so in order to comply with architectural specifications. A Berridge dedicated-profile portable roll former is designed to form one specific profile that precisely conforms to the panel specified by architects when Berridge coil, Vinyl Weatherseal, and other accessories are utilized. Several Berridge dedicated-profile roll formers also have special attachments which automatically insert the patented Berridge Vinyl Weatherseal during the roll forming process.”
When MetalForming studied the market for portable roll formers, it was quite apparent that most customers wanted multiple profile roll formers according to president Geoff Stone. “However, nearly all complained about the complexity of changeovers,” he says. “Not only was time and labor a factor but also the quality of panels came into play. This is precisely why we invented the Quadro roll former. Our design criteria included changeover from one to five minutes and elimination of operators changing and gapping rolls.”
Stone says Quadros are typically purchased with four profiles loaded: mechanical lock, u-panel, snap lock with clip, and nail strip. “Changeover from one to another ranges from one to five minutes,” he says. “If a customer wants other profiles such as soffit, 2-inch structural mechanical or 1-3/4-inch structural snap lock, he unbolts four bolts, removes his existing cassette and slips in the new cassette — elapsed time is five to 10 minutes. This also reduces training time to as little as three hours.”
Stone says if a customer wants a second machine, he can buy it fully equipped or buy the machine base only and use cassettes from an existing machine. “They are completely interchangeable,” he says. “This results in total flexibility.”
The Quadros are modular so a customer can add ribbing, striation, longitudinal slitting, concave curving, hot melt for weather tightness, perforating, and even automatic pre-notching for the eaves edge.
“We also know, however that there are customers who use only one profile because they serve only one market — for example — residential nail strip,” Stone says. “Thus, we provide the Quadro LTD for those customers at a substantially lower cost.”
Ewald Stellrecht of ESE Machines finds it hard to believe that someone would invest in a multi-profile machine. ESE Machines manufactures only single-profile machines, and sells them to one-man operations as well as large manufacturers who only use the machine in-house. “If you’ve got one crew, they take one machine and run one profile,” Stellrecht says. “With any one job, you’re only going to need one profile. You don’t put different profiles on the same roof.
“My machine costs about $25,000 and the multi-profile machines can cost $80,000. Do you want to spend $80,000 on one machine that can keep one crew working, or do you want three machines with a single profile that can keep three crews working at the same time? When you’re just starting out, why would you want to indebt yourself with an $80,000 machine?”
Is there a profile you want but haven’t seen offered by a roll former manufacturer? Are you looking for something truly unique? Roll Former Corporation offers custom machines for metal roofing panels, as well as drip edges, rake trim, valleys, ridge caps, and crown molding. John Dumke, Roll Former’s director of sales and marketing, says some of his customers are referred to him by competitors who can’t or don’t want to get into custom machinery, including seamers for custom profiles. “We can design it, make it from scratch,” he says. “Probably 60-70 percent of what we do at this point is custom machinery.”
Roll Former offers a multi-profile machine, the VS-150 that is built to offer up to eight profiles. “That’s our bread and butter machine,” Dumke says. “Most of the roofing contractors I talk to, some are larger companies, but most are six men and two pickup trucks. They don’t always have the manpower to deal with lengthy changeovers.”
Dumke says changeovers on the VS-150 can take anywhere from 15 minutes up to an hour between the 1-inch and 1-1/2-inch standing seam panels. “We try to keep it simple, make the machine user friendly.” Roll Former provides training at the customer’s location for a cost and offers free training at its Pennsylvania offices for an unlimited number of employees.
Both Zimmerman Metals roof panel roll formers are set up to manufacture multiple profiles. The company’s commercial machine can handle eight profiles, including structural panels, and the architectural machine has the ability to run five profiles. Any purchase includes extensive training at the customer’s location, including follow-up training with the purchase of new tooling.
“I don’t think there are too many single-profile machines out there anymore,” says Pearson. “We’ve had some customers who use them that way and they’ll come back and buy a second or a third machine even. They can run panels at different sites. It’s rare that they would need different profiles on the same job.”
Pearson says 75 to 80 percent of Zimmerman customers purchase a machine to run just one profile. “Typically, they come back to purchase another profile or two,” he says. “Often the profile preference depends on regional requirements.”
According to Pearson, a new tooling can be sent out in 1-2 weeks. “We try to stock everything customers need,” he says. “Typically, we have a half-million to $1 million in parts on the shelf.”
That’s one way the roll former manufacturers help you fatten your wallet.

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Details count for horse barn builder

by Ryan Reed
Ken Meigs has been a builder in the Black Earth, Wis., area for decades, and he hears about every big project in the region. Horse barns have become increasingly important to his business, especially as wealth from nearby Madison trickles into the surrounding countryside.
So he didn’t blink when a lumber yard employee mentioned that a developer was planning a big horse facility. The building, including a 28-stall horse barn, a riding arena, and other amenities, would serve as the focal point for an entire subdivision: the Carriage Ridge Equestrian Community, planned by Tom Bunbury of Restaino Bunbury Associates Realtors.
Meigs, a dealer for Wick Buildings, based in nearby Mazomanie, sent the developer a letter, along with photos of his work and Wick Buildings’ literature. He also sent copies of the April 1997 Frame Building News, with a photo and description of the 25,000 sq. ft. Foxwood Farms facility in Holly, Mich., built by Wick dealer Dick Alwood of Sentry Corp., which won the National Frame Builders Association Building of the Year Award for large horse barns.
But Bunbury, it turns out, was already talking to a different post-frame package company about the barn. Meigs’ package got Bunbury’s attention, however. Meigs came up with some numbers, and those also impressed him. But the developer still wasn’t convinced that Meigs, and Wick, could handle the details of the complex project.
To win him over, Meigs resorted to a tried-and-true business technique: take the client to dinner. He met Bunbury at Rookies, a local restaurant owned by shoe mogul Steve Schmitt. The restaurant had been thoroughly remodeled into a state-of-the-art sports-themed pub and eatery, including a miniature baseball stadium (105 ft. to straightaway center) and walls and ceilings lined with jerseys, photos, posters, and other sports paraphernalia.
When the dinner conversation turned to business, Meigs casually mentioned that he’d been general contractor on the remodel. His company had performed the demolition and the framing, but he’d also coordinated the work of more than 30 subcontractors. In addition to the usual electrical, plumbing, heating, concrete, paint, etc., there were specialty installers for the sound system, televisions, signage, and a unique air handler system for clearing cigarette smoke.
“He came in here and looked around,” says Meigs, “and that convinced him we could handle the details.”
Meigs got the job, but the design still needed some tinkering. Bunbury originally planned two separate stall barns, but site drainage and grading requirements wouldn’t allow that building layout. Discussions went back and forth on many topics; all told, the center underwent some 20 revisions.
With help from the engineering staff at Wick Buildings, the final design took form during the summer of 1997, and Carriage Ridge was built in late 1997. Although Meigs has his own crew of eight or nine, Carriage Ridge was erected primarily by a Wick crew.
The stall barn wound up at 72x132, with room for two tack rooms, two wash stalls, two grooming stalls, and two feed stalls among the total of 28 stalls. The riding arena measures 72x184 ft.
The stall and arena ceilings are finished off in white steel panels fixed to the trusses. “It’s an upscale way to finish a horse barn, but we’re doing a lot of it,” says Meigs. The look is clean and light, hides the insulation, cuts down on rain noise, and the trusses don’t get dusty or become home to birds. Insulation in the form of 2-in. fiberglass blanket with a built-in vapor barrier keeps the interior comfortable year-round.
The 36x36 viewing area, complete with a half-kitchen and couches, was built with large windows onto the riding arena. Meigs finished off the high ceilings in t&g cedar.
The stall barn features a trough conveyor system, built by Patz Manure Solutions, for speeding manure and bedding disposal. The systems are most often installed in dairy barns, but they work well for larger horse operations. For Carriage Ridge, the conveyor runs in a foot-deep trench at the back of each stall, and is easily accessible by lifting a steel plate. Such systems are occasionally installed to run outside the stalls, but this means the waste has to be shoveled into the aisle, and can hinder access.
The Carriage Ridge project spawned others for Meigs. A year ago Curt Mueller, a local sports products entrepreneur, contacted Meigs about building a modest 30x60 stall barn on his property. Halfway through the design process, the client decided to add a riding arena, but his ideas on size kept changing. “I thought he needed a sense of scale to the numbers he was coming up with,” says Meigs, “so I took him out to Carriage Ridge to have a look.”
Mueller was impressed, to say the least. The facility ended up at 72x336, plus 9-ft. overhangs on each side. About half of the building is used as storage, with a stall area, a riding arena, and a viewing room under one roof at the other end. Like Carriage Ridge, the stall area and arena are insulated and finished off with steel ceiling panels. A viewing room, lined with t&g cedar, includes a partial kitchen and lounging area.
Not all of Meigs’ projects are so large or luxurious. His company recently completed a two-stall stable that combines features of a run-in shed and a horse barn. The basic idea came from the owner, Don Kirch, and was fleshed out by Meigs’ sales supervisor Dan Lucey. Like other barns, the building includes a tack room, storage areas, and an office. The stalls themselves are open to the outside, however, with Dutch doors at their rear.
“I built a horse barn for him years ago,” says Lucey, “and he liked it but thought it got too hot in the summer. He wanted a design that allow maximum air flow.”
With the limited time the owner could spend on his site, he thought it best to give the horses maximum freedom of movement.
“The barn is situated in a valley with pretty good airflow,” says Lucey, “and we set the building east-west to catch the breeze.” Most of the winter storms in the area come out of the north-west, so wind and blowing snow wouldn’t be severe.
The unique design required some tinkering, but Lucey worked out most of the details before construction. The only problem with the open design was birds, which tried to nest in the trusses. Lucey installed some blocking and a steel ceiling, and the problem was solved.
Improvisation is par for the course in horse barn design. “Every horse owner has a different idea of what’s right,” says Meigs. The final design is usually a trade-off between those ideas and practical and financial concerns. “A lot of people want a hay deck above the stalls,” he says, “but they never consider how to get the hay up there.”
Meigs has been in the business so long he can’t say how many horse barns he’s built; somewhere between 50 and 100 is his best guess. Equestrian work is about a quarter of his business, with commercial and residential projects making up the bulk. Farm business has dwindled to less than 10 percent.
One of Meigs’ newest business prospects is at the other end of the scale from Carriage Ridge: a small, 12x20 run-in shed that he sells installed for about $3000. The shed, suitable for horses as well as smaller stock like sheep and goats, can be assembled on-site or prefabbed. The structure is most often mounted on skids, so owners can move them by tractor to different paddocks as desired. The portability also avoids the property taxes on fixed shelters.
Meigs has one of his portable run-in sheds by the side of the road near Mazomanie as advertising, and is getting a lot of calls on it. “We’ve built about seven or eight just this year,” says Lucey.
But the big projects keep coming as well. Meigs engineer and salesman Dave Budden says Wick has built nine or ten Carriage Ridge-style facilities in the past few years, and the demand keeps growing.
Apparently, there’s enough money in the economy to support some lofty dreams. It seems to be a very good time to be a horse.

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Metal roofs at home in the country

In just a few decades, metal roofing has gone from has-been to major contender in steep-slope commercial and institutional roofing. But it’s the residential market that the industry has been eyeing lately, especially those vast tracts of suburban homes now covered primarily with shakes or asphalt shingles.
Many builders are starting to recommend metal roofs to clients, and for good reason. The low maintenance and long warranties make for satisfied clients. Like any other upgrade, there’s a profit margin involved. And 10 or 20 years down the line, when you bring a customer by to see your work, the home is less likely to have a curling, discolored roof.
But metal roofing runs into a number of obstacles in the residential market. Cost is one, of course: metal roofs generally run more than twice the price of 3-tab asphalt shingles, in the same range as concrete tile and wood shake.
But a bigger concern, especially in tightly built suburban and urban housing tracts, is aesthetic: many homeowners don’t want to flout the dominant roofing style of a community, which is often dark-colored shingles or shakes. Light-colored or unpainted metal can create fears that glare will disturb neighbors. Oftentimes, community covenants actually forbid certain materials to maintain a desired look.
Tellingly, the objection most often heard is that vertical panel roofing looks “too rural” or “too commercial.”
For these reasons, only metal shingles and facsimile products — metal formed and finished to mimic shakes, tiles, or asphalt shingles — have relatively free access to these markets. Vertical panels may end up on custom homes and a few others, but haven’t made a dent in those vast suburban tracts.
But for builders active in less dense suburbs and rural areas, metal roofing is a natural fit. The more open neighborhoods allow for distinctive designs and less stylistic conformity. Brightly colored roofs are less likely to bother anyone or offend community sensibilities. And rural dwellers are more likely to have a first-hand appreciation of the durability and looks of metal.
In some regions, residential vertical-panel metal is an established architectural style. The Texas Hill Country style, the Florida “Cracker” house, the northern New Mexican vernacular, and the rural Southern 5-v crimp look are the best known, but there are areas of the Upper Midwest and West where vertical panels are common. Not coincidentally, these are primarily rural traditions.
For many homes, screw-down panels suffice to make an attractive roof. With good quality products, the exposed fasteners aren’t visually intrusive, and the ribs limit metal’s propensity to oilcan, or warp. Homeowners, however, should keep an eye out for fastener pullout over time.
Where it’s affordable, standing seam is preferable for its cleaner lines and fewer penetrations. Field-seamed panels are the gold standard, but snap-lock and the flange-fastened (nail-strip) panels can lower installation costs.
If the customer doesn’t like the vertical panel look, but is willing to pay for a premium roof, it’s time to turn to shingles — metal shingles. The variety here is huge, ranging from copper tiles and painted metal shingles to products that are almost indistinguishable from tile and wood shake. Metal shingles can also offer a look unlike any other material, including the Victorian stamped style popular a century ago.
Many shingles are installed on a batten system, which makes them ideal for reroofing directly over asphalt or wood shakes, without tear-off. Others require a clean deck.
For most homeowners, metal’s cost is still the biggest obstacle. In new construction, the roof material is often one of the last topics discussed, arising at a time when the client is tired of upgrading. Asphalt shingle roofs are effective, easy to install, and inexpensive, and they’ve convinced most homeowners that roofs should be cheap and replaced every 12 to 20 years. Homeowners might spend big money on triple-paned glass but still insist on a cheap roof.
The fact that the roof represents a huge portion of the building’s visible exterior means it should be handled at the outset. Other than aesthetics, there are several points that can help convince a homeowner.
Value. Depending on the system, a metal roof can last more than 50 years. Its cost should be compared with the life-cycle cost of a series of asphalt shingle or shake roofs, including tear-off and reroof costs.
Fire. Forest and brush fires are a fact of life in many parts of the country, and metal has always been viewed as the premier fireproof roof. Fire officials in the West this past summer were reportedly favoring metal-roofed homes when choosing which to defend. In new installations, the model codes consider metal a Class A roof. More importantly, metal will remain a Class A even after decades of real-world UV and weather exposure.
Snow. Metal sheds snow and can’t be torn off like wood shakes, tiles, or shingles; this makes it ideal for weekend cabins that can’t be checked or frequently maintained. The air gap below most metal shingles can also help keep the roof cold during snowy winters, helping to prevent ice damming.
The environment. More than 20 billion pounds of asphalt shingles end up in dumps every year. Metal’s recycled content averages over 50 percent, and it’s 100 percent recyclable.
Energy. Metal may get hot in the sun, but it performs surprisingly well as cool roofing. Light-colored metal deflects the sun’s heat energy, and, according to a Florida Solar Energy Center study, it can lower attic temperatures and cut cooling costs better than any other material. And new pigments currently undergoing tests will allow even dark-colored painted metal to reflect like light-colored materials.
Metal shingles, whether installed on battens or not, generally create an insulating air gap beneath them that can also reduce heat transmission.
Wind. Most metal systems are thoroughly tested for wind uplift, and perform impressively. Metal products don’t require extra nails or wires to pass; the basic installation is usually the wind-rated installation method as well.
Hail. Virtually every metal roof panel submitted to the UL 2218 hail impact test has passed with the highest rating: Class 4. Other materials perform so poorly their manufacturers have resorted to attacking the test rather than improving the product.
In Texas, insurance discounts are available to homeowners who go with Class 4 materials. Homeowners must sign a waiver on aesthetic damage, however, which has dampened participation in the program.
Weight. Not all homeowners need to consider weight, but for those who do, metal’s featherweight ranking (90-150 lbs. per square, compared to 500-1000 lbs. for tile and 300-400 lbs. for each layer of asphalt) can be indispensable. In particular, achieving the tile look isn’t possible on some structures without using metal facsimiles.
This has been a brief overview of a complex and varied topic. Readers interested in learning more should request literature from the manufacturers in our product profiles beginning on page 38, visit the Metal Roofing Alliance Web site, www.metal-roofing.com, and consult our sister
publication, Metal Roofing magazine (for subscription information, visit www.metalroofingmag.com, or fax your request to (715) 445-4087).

Source constructionmagnet.com

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Metal roofing: At home in rural America

by Ryan Reed
Contractors accustomed to post-frame and metal building erection might have a hard time seeing metal roofing as a hot new trend. For these systems, metal is simply the most practical roof because it’s structurally efficient, quickly installed, and likely to last the life of the building.
But anyone with eyes knows that metal has been cropping up more and more on commercial and residential structures alike. And it’s not just shopping center mansards or backwoods homes anymore. In the past ten years, metal has become the choice of architects for upscale projects, property owners tired of the maintenance associated with other materials, and schools and public buildings, both for the long-term cost savings and to meet some municipalities’ goals to use recycled and recyclable materials.
The rise of metal roofing to architectural prominence has been spurred by better materials, improved forming processes, and superior finishes. High-speed lines, jobsite roll formers, seaming machines, engineered panels and clips, and a host of other developments have raised the quality of metal roofing while holding its price down.
This transformation hasn’t exactly passed by the rural contractor. Most appreciate the improvements in paint systems and substrates. But they’re also happy with a limited assortment of metal panels, whether for wall or roof application.
And why not? Through-fastened ribbed panels, dismissed as “crap-lap” by standing seam installers, have served to inexpensively roof a generation of horse barns, utility sheds, garages, cabins, and quite a few nice homes as well.
But times are changing. As builders continue to diversify into larger and more complex projects, and as city dwellers continue moving their homes and bank accounts into the countryside, it’s clear that many contractors will be encountering demand for a broader range of roofing styles and more expensive materials. It may be sooner than later that a customer asks about a standing seam copper roof.
More likely, builders will find they can offer customers a tile or a shake roof on a building because metal versions are available in the weight and engineering values required. These variations can add value and interest to otherwise cookie-cutter projects. The fact that these facsimile products could outlast the materials they imitate is just another selling point.
Metal roofs aren’t all about durability and quality. A lot of metal is specified or requested these days for entirely aesthetic reasons. The architectural use of bare Galvalume and galvanized is often more a “reference” to a rural aesthetic than an attempt to provide the best roof for the money.
The desire for the “authenticity” of old metal has even led some Southwestern builders to use rusting corrugated steel as roofing. The material rusts evenly and looks quite sharp. Guaranteed to fail, of course, but in that climate it could last decades.
In other words, for all the progress in metals, profiles, and finishes, metal’s heritage is as important as its chemistry. And that heritage is largely rural.

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The demands of dairy

by Ryan Reed
The movement from modest stanchion and tie-stall barns to large, open freestall facilities over the past three or four decades represents more than just a change of building styles. The rise of the freestall barn is only the most visible aspect of a transformation in the culture of dairying. In the past few decades, small operations based on family labor have given way to professionally managed businesses with a wage-earning, clock-punching work forces. Grass-eating cows, sometimes even with names, have been replaced by confined, computer-monitored animals that produce staggering amounts of milk for a few years, then are culled. Many of the wood-sided gambrel barns scattered across the rural landscape lie abandoned in favor of massive facilities that efficiently convert protein-rich feed into milk and manure.
The freestall revolution has been driven by new feeds, dairy parlor technology, cow comfort research, computerized herd management techniques, and milk prices that have created an unrelenting pressure to lower production costs — as well as by the lifestyle aspirations and values of a younger generation of dairy operators.
Like any revolution, the freestall movement involves gains and losses. Nostalgia may be on the side of the small operations, but the economics of milk production sure aren’t. Many northern tier states have been losing four dairy farms per day for several decades. Smaller stanchion and tie-stall operations may not be doomed yet, but their heyday is definitely past.
Luckily for builders, the move to freestalls also involves a lot of new and very large farm structures. Thousands of freestall barns, ranging from 200 to 2,000 cows, have been built since the 1970s. Rising milk prices made for a booming building market in the 1990s, and low interest rates have kept builders busy expanding existing facilities despite the low prices. Most contractors contacted by Rural Builder noted a softer market for dairy facilities in the past year. Some worry that a rise in interest rates could sink a lot of dairies with high debt loads.
Still, the freestall boom isn’t over yet. There are many areas of the country with large concentrations of smaller stanchion and tie-stall barns. University of Wisconsin Extension professor David Kammel says small barns still make up the majority of his state’s dairies — meaning there’s still a lot of potential freestall customers out there. Most builders were optimistic that milk prices would rebound, and the building with it.
But it’s not all about milk prices. While corporations have taken control of much of the West Coast dairy business, elsewhere in the country freestall operations are mostly built by longtime dairy families that have reached the point of generational change. Often it’s a family with two or more children wanting to take over, says Phil Martin, of Fingerlakes Construction in western New York, and they realize they have to get big to support more than one family. Others just see the economic forces at work. “They see what happened to poultry and hogs, and say ‘I’ve got to get myself big,’” says Ken Ramsay, design engineer at Lester Building Systems’ Charleston, Ill. regional center.
Freestall barn design has evolved over the decades. Eave heights have risen as the overriding importance of ventilation became clear. Alleys have widened, with automated systems such as feed conveyors giving way to drive alleys for trucks mounted with TMR (total mixed ration) mixers. Optimal cow bed dimensions have changed, prompted by research conducted by universities and consultants. Scrape and flush manure systems have been perfected, flooring types investigated, and bedding material tested.
Despite four decades of constant tinkering and experimentation, there’s still a great deal of variation in how dairies are laid out, built, and finished off. “You look at hog building, and they’re almost all the same width, the same column location, very standardized,” says Ramsay. “With dairy, you’ve got many different building widths, depending on the number of rows and the farmer’s preference for alley and stall spacing. Even those with the same width, the column locations are different.”
In designing their dairies, says Ramsay, “Farmers tend to look at a lot of buildings, and they know what they want. They tour around, and make lists of what they think works.” Low milk prices force farmers to view everything in terms of production costs. While freestall barns are relatively simple structures, their size makes every decision critical; a simple condensation blanket in a big barn can run $35,000.
But dairy operators are also a notoriously independent lot, and they often stick to their own ideas and resist standardization. “Farmers are constantly modifying their facilities, constantly fine-tuning things,” says Dean Widrick of Widrick Construction, Adams Center, N.Y.
Most builders can accommodate whatever details a dairy operator or consultant wants, within reason. But most also have an opinion on what works and what doesn’t. Rural Builder asked a handful of dairy builders their views on some of the more important of these details.

Rafters vs. trusses
Common trusses are inexpensive and create long clearspans that offer maximum interior flexibility. But many, if not most modern freestall barns are constructed not with trusses but with rafters, usually laminated veneer lumber (LVL) but sometimes engineered I-joists, glulams, or steel beams. They are supported by steel or wood columns, knee-braced at the perimeter (diaphragm design doesn’t work with the open end and side walls) with four interior columns set between alleys. Purlins are inset between rafters on draped hangars.
The idea behind the open rafter system is to reduce the locations where birds could perch or nest, thus improving the barn’s overall sanitation and minimizing bird droppings in feed aisles. Some believe it also facilitates air circulation in the barn. The system was introduced by Lester Buildings, and by all accounts has been both wildly popular with operators and widely imitated.
Rafter construction is more expensive, and not everyone thinks it’s worth the money. Martin, who’s sold freestall barns for 20 years, thinks the design’s primary appeal to dairymen is unrelated to its practicality. “The old farmers come out of their tie-stall barns, these cramped, dark dungeons, they’d go into a rafter barn and just be amazed by the openness, the height of them. They look great.”
As for their effect on birds, “They’re a waste of money, and don’t do a thing,” says Martin. “Truth is, if you’ve got birds on the farm, you’ll have them in the freestall; they’ll perch on the stalls, the head locks, anywhere.” Martin, whose 1,000-cow Danielewicz Dairy freestall expansion won 2002 Building of the Year honors from the National Frame Builders Association, generally uses a three-part roof, with a central truss and rafters along the sides.
Tom Jackson, who sells Wick Buildings in southern Wisconsin, agrees. He sticks to traditional trusses in the center of freestalls, with either LVL rafters or parallel-cord trusses at sides, and has no reports of bird problems. “Microlams are expensive for my area, and hard to justify,” he says. His customers appreciate the interior flexibility for alleys and stall layout. And if bird problems arise, says Jackson, the farmer can always retrofit products such as Birdblox or netting.
Still, birds are a serious nuisance for many dairymen, and most accept the notion that minimizing perches is worth the extra money — sometimes a lot of extra money.
Lakeside Systems in New Holstein, Wis., has used a third option: a solid arched truss, made by Starwood Rafters, that combines glulam, plywood, and dimensional lumber. The design offers a wide clearspan with no nesting and very limited perching spots for birds.
Other options include steel I-beam rafters, often used with wood purlins, and even standard pre-engineered steel building trusses. While a few dairies are choosing metal buildings, it’s generally an expensive option, says Widrick. If freestall barn widths increase, however, expect to see a lot more steel structurals.

Insulation
Insulation is a hotly debated topic in dairy barns. Stanchion barns are kept relatively warm for the benefit of the workers tending and milking the cows; the cows, however, do just fine with the wide temperature ranges that nature affords. The emphasis on ambient temperatures and ventilation is one of the chief characteristics of freestall barns, which are essentially shaded windbreaks.
Insulation, of course, is generally used in milking parlors, again for worker comfort. Holding areas leading to the parlor are usually partly insulated to moderate heat loss from the parlor. But in freestall areas, experts urge producers to allow ambient temperatures to prevail: “Any attempt to temper barn air so that it is more than 5 degrees C warmer than outside conditions has been shown to result in poor air quality,” says Cornell University ag engineer Curt Gooch.
“The benefits of insulation are minimal, the presence of insulation in a building may lead to mismanagement, and the initial cost of insulation can raise the cost of the building significantly,” Gooch said at a recent freestall conference. “The extra cost associated with purchasing and installing insulation does not affect cow performance; therefore, producers are advised to use capital funds to install fans and evaporative cooling equipment, as this will benefit the cows during heat stress conditions.”
So much for expert opinion; many dairymen ignore the advice. Insulated barns are still common in the Dakotas, says Ramsay. Mark Mashlan of Fox Structures in Kaukauna, Wis., says he uses insulation in about half his dairies; Larry Speitz of Valley Building Systems in Little Chute, Wis. insulates three-fourths of his.
The materials most often used aren’t very insulative, of course: usually a 2-inch or less laminated fiberglass blanket, or a rigid polyisocyanurate board. Speitz has also used foil-faced reflective insulation on occasion.
The primary motivation for insulating barns is to lessen cool-weather condensation, which creates indoor rain and can lead to roof panel corrosion. Other reasons include moderating temperatures for worker comfort; preventing manure from freezing in alleys; and minimizing peak temperatures that can cause heat stress and lower cow productivity.
Gooch believes proper ventilation is the better answer to condensation problems and heat build-up, and suggests flooring solutions for manure freeze. There are two additional concerns with insulation: birds can wreck some insulations and use it for nesting. And rigid insulation, says Ramsay, can interfere with the transfer of design loads from roofing to purlins by creating a gap that a fastener must bridge.
Lakeside’s Steffes still recommends an insulated condensation barrier in his freestalls. “One guy didn’t want it, and the next year we were back pulling off the roof to retrofit the material. They couldn’t take the constant dripping.”
Some farmers even want full insulation. On one of Steffes’ projects, 6-inch fiberglass batts were inserted between purlins, with a PVC panel screwed in place to form a slick ceiling. “That place stays in the 40s when it’s below zero,” he says.
Whether insulation will ever pay for itself, whether in cow productivity or by protecting the steel from corrosion, is a different matter.

Ventilation
Most modern freestalls use open ridge ventilation, with the gap fitted with poultry netting to keep out birds. The rafters or trusses must be flashed or otherwise protected where exposed to the weather. The open ridge is usually centered over the drive alley, and so is often not appropriate for a barn with an odd number of rows.
Overshot ridges are a bit more expensive, and seem to be a regional or even local variation. They usually have a short upstand on the low side to lessen snow intrusion, or a curtain that can be closed. Overshots should be oriented away from prevailing winds, however, as one builder learned the hard way one snowy winter.
Holding areas often have ridge vents with caps to prevent the entry of snow and rain. Valley Building hangs a 12-inch PVC pipe that can be raised up in frigid weather to loosely close off the vent.
Continuous raised ridges are often used to increase the drafting force on ridge vents. Chimneys can also be used to accelerate ventilation.
The latest trend, still rare, is to eliminate ridge vents entirely and set up fans to induce tunnel ventilation: an old stanchion barn technique reinvented for the freestall.

Footings and columns
Most freestall barns are still built with traditional post-frame embedded columns at their perimeters, offering a strong connection to transfer design loads. A lot of builders, however, are turning to perimeter concrete footing walls, set on piers, that can be incorporated into the stall design.
Interior columns are often steel; operators often want to be able to weld gates and other hardware in place, and steel also stands up well to the occasional smack from skid steer loaders in the feed alleys. Whether wood or steel, interior columns can be set on curbs that separate alleys, with footings incorporated into the curb design. In theory, this allows concrete work to be completed all at once, before the building contractor even arrives. Placing columns on raised footings also sidesteps some manure seepage concerns that some states are having, says Ramsay.
Builders should be aware that proper anchorage of columns is often neglected, says Ramsay, since it falls between tasks delegated to builder and concrete contractor.

Steel vs. aluminum roofs
Both galvanized steel (G90 is recommended) and aluminum are used for dairies. It is critical not to use Galvalume material for cattle and hog operations, particularly in cold climates, because the condensation can cause pitting corrosion.
Aluminum carries a higher price than steel, but stands up to moisture-induced corrosion much better, and should outlast steel. Some builders have seen steel rust out in less than a decade, and swear by the lighter material.
The downside to aluminum is its higher coefficient of expansion, about twice that of steel, which means that longer panels will put more stress on roofing fasteners. As a softer material, aluminum will more easily “slot” beneath the fastener, creating potential sources of leaks. According to Fabral’s Bill Croucher, through-fastened aluminum panels should therefore be limited to 16-foot lengths, with longer spans end lapped. Steel panels can be installed in lengths up to 40 feet.
The choice of metal is strongly regional. Nearly all Midwestern barns use painted steel, says Ramsay, while the preference for aluminum is strongest in New England, New York, and Pennsylvania. Like many other dairy features, the choice probably has more to do with a handful of regionally admired and imitated facilities than anything to do with the climate.

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Horse Barn Builder: Following his passion

by Mark Ward, Sr.
Some people go into the restaurant business because they figure that whether the economy is up or down, people will always need to eat. Others go into homebuilding because they know that sooner or later people will be looking for a nicer place to live. And Greg Thompson, owner of Cross Creek Construction & Design in Burton, Texas, entered the barn building business knowing that people will always ride horses.
Thompson first honed his construction skills as a carpenter, then as owner of a construction firm specializing in commercial interiors for the bustling Houston metro market. “It was a great business to run during the boom times of the 1960s through mid-1980s, when Houston was the capital of the Energy Patch,” he recalls. But then the Texas energy boom went bust and Thompson had to decide his next move.HBB-CrossCreek1.jpg
A lifelong horseman and owner of a small breeding farm in the rolling Texas hill country, Thompson figured he could make a living by servicing other people who shared his passion. “Texans have loved their horses since the days of the old vaqueros,” he points out, “and it seemed like that would remain a constant, whatever the economy was like. Besides, I’ve had horses since I was eight years old so I’d rather build barns than anything else!”
Thompson and wife Trish had bought their own farm in rural Brenham in 1981 to breed paint horses and quarter horses. “We were already spending half our time there, anyway,” laughs Greg, and so in 1991 he closed his Houston construction business and set up shop in the countryside as Cross Creek Construction & Design.
Fifteen years ago, Thompson knew he was taking a calculated risk that the hill country — roughly between Houston and the state capital of Austin — was ripe for development. With the state struggling through the lingering effects of the regional energy bust, as well as a nationwide economic recession, the risk of launching a rural building business was real. But soon enough, it became clear that Thompson had bet on the right horse.
Between 1963, when Thompson graduated from college with a business degree and started in construction, and 1991, when he founded Cross Creek, the greater Houston area had grown from half a million residents to more than 2.5 million. Moreover, the area around rural Burton, Texas, was starting to emerge as true horse country. With the oil industry encamped in Houston and the state government housed in Austin, affluent professionals started buying up rural acreage as the economy picked up steam throughout the 1990s.HBB-CrossCreek2.jpg
“I started by building horse barns for people who were buying some property in the country,” Thompson recalls, “and then, when they had the money to also build second homes, that got me into custom homebuilding as well.” In the last 15 years, he reports, the population around Burton has quadrupled. Today about two-thirds of Cross Creek’s business is equine construction, with the remainder coming from custom homes, equipment buildings, sheds, and feed stalls. The dozen projects Cross Creek performs each year range in value from $150,000 to $1 million, with an average project coming in at $300,000.
About 75 percent of his business, Thompson figures, comes from simple word-of-mouth. Yet he also generates “a lot of business from friends” through his longtime involvement and personal networking in several historic Texas institutions. One is the Houston Livestock Show and Rodeo, an annual event that boasts 32,000 sustaining members; 17,000 show volunteers; 92 committees; 33,000 livestock and horse show entries; 300 commercial exhibitors; and some 1.8 million attendees who pack the same Reliant Park sports complex where the NFL Houston Texans and baseball’s Houston Astros play.HBB-CrossCreek3.jpg
Another organization in which Thompson is active is the Tejas Vaqueros, which upholds the heritage of America’s first cowboys. And with a third group, Ranchers Ride, each year he joins with 300 fellow members in recreating an historic Texas trail ride.
Cross Creek’s projects begin when Thompson hosts his client in the office he maintains within his own horse barn. “We have the initial meeting there,” he explains, “so I can show people the quality of our construction and what we can build.” From there, he and the client may visit other Cross Creek barns to get ideas about design and function.
Thompson does not build his projects with a construction workforce of his own, but outsources the work to local subcontractors. “What I bring to the project,” he believes, “is the fact that my customers can see that I really know horses. My clients are often oil company executives who would rather hire a general contractor than have to do the general contracting themselves. So I oversee the whole project, not just the building shell but everything from siting and roads to stalls and fences.”HBB-CrossCreek4.jpg
A recent example is the $1.5 million Pegasus Ranch project Cross Creek built for David Andras, owner of the Houston Polo Club’s Pegasus team. The Washington County stable includes 24 stalls, each 12x12, which are divided between four wings. One wing features a farrier room and another a wash bay, and both are floored with rubber pavers. Each of the stalls is constructed from stained cinderblock and finished with custom doors.
A 1,400-square foot center area called “the hub” contains an office with full bath and walk-in closet, large tack room with custom saddle racks and custom cabinetry, a groom’s lounge, a powder room, and a feed room that also serves as a tack room for guest riders. The hub area has a scored and stained concrete floor and is climate controlled with central heating and air conditioning.HBB-CrossCreek5.jpg
The exterior of the central hub area and the front walls of the stalls rise to a height of 12 feet, and 36-inch exterior alley walls around the entire building are made of cultured fieldstone. The four arched entries also are stone. On each of the four sides of the center hub are four saddling paddocks each with a floor of rubber pavers and custom ironwork. The building is crowned with five cupolas — 4x4x5 on each of the four wings, 8x8x9 in the center — and a center copper weathervane.
“The initial challenge of the project,” says Thompson, “was designing a 14,000-square foot roof in the shape of a cross and with 12 roof valleys. Also, each end of the four wings had its own hip roofs with gable louvers.” Yet from the initial meeting with Andras in June 2005, and the groundbreaking in August of that year, the project was completed in impressive time and ready for occupancy by May 2006.HBB-CrossCreek8.jpg
In his 15 years as a horse barn builder, Thompson says — and the Pegasus Ranch project illustrates — that equine facilities “have generally become bigger and fancier, while at the same time people are attracted to low-maintenance building materials. To give clients the custom touch they want, for example, we fabricate all of our own stalls, grills, and gates.”
Yet ironically, even if the barns have changed, the customers haven’t. “I’m doing construction for the same kind of people — oil company executives and other professionals — who were my customers when I built commercial interiors back in Houston,” he explains. “But back then in the big city, I had to manage a construction company with 35 employees. Now I just work with my wife Trish, who designs our custom-home projects, and my daughter Cori, who has a background in accounting and administration.”
And as compared to his former career as a big-city commercial builder, Thompson says that as a rural builder “I can still build great buildings for people who have exacting standards. But I can scale down and enjoy a lifestyle that’s worth living, and concentrate on projects that reflect the things I’m passionate about.”

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Classic Look of Metal: Copper

The Copper Development Association College reunions, for some alumni, are times to have fun, kick back and reminisce about the good old days on campus.

For the 30th reunion of the Dartmouth College class of ’78, raising a $40 million endowment was just one more item on its agenda.

Classic-Dartmouth1.jpgThe $40 million happens to be the price tag for naming a new campus building that will carry their legacy far into the future. The Class of 1978 Life Sciences Center is one of several facilities planned for construction on the Dartmouth campus during the next few years.

The 174,500 square-foot building will take its design cues from the “traditional” architecture of the campus. Identifying features include a brick exterior (with or without ivy), granite base and a handsome, pale-green copper roof to cap off the project, according to Steve Campbell, Dartmouth’s director of planning, design and construction.

Because it can take years for copper to achieve a green patina — a natural barrier that protects the metal and contributes to its legendary lifespan — the new building’s roof will be pre-patinated before installation, a process that accelerates the color change. This will allow the structure to more quickly blend into its surroundings.

Copper is visible on most of the roofs across the Dartmouth campus in Hanover, N.H. Originally, slate was predominantly used, but the university gradually transitioned to copper through building additions and renovations. “Copper just seems to fit well with our architecture,” says Jack Wilson, associate director of planning.

Wilson is responsible for selecting architectural materials for Dartmouth. While the college does not have specific architectural guidelines, he feels the campus buildings in general adhere to two existing, predominant styles: neo-classical and neo-Georgian. “You’ll find copper on all the pitched roofs on campus,” he says. “It really sets the tone.”

Within its exterior of copper and brick, the new life sciences building will house an array of laboratories and specialty classrooms that support Dartmouth’s commitment to biological research. Included in the structure are features such as a 200-seat auditorium, two-story atrium, 30 “wet” labs, six teaching labs, two 80-seat amphitheater classrooms and a 6,000 square-foot greenhouse.

Appropriate to its mission, the life sciences center will be environmentally friendly. The building is expected to consume only half of the energy typically required to operate similar laboratories currently in use in the United States. State-of-the-art energy management and storm-water management systems are key features included in the design.

The project is estimated to cost $93 million when it is completed. The class of ’78 is planning to tour their newly named building sometime around March 2010, the proposed opening date.

“The class of ’78 is not only extraordinary generous, but farsighted in enabling the work of students and faculty in critical fields” such as life sciences, says Dartmouth president James Wright. “I’m excited by the prospect of having a building that not only is on the (architectural) cutting-edge for the space it provides, but will also be a national model of sustainable design.

The Copper Development Association is the information, education, market and technical development arm of the copper, brass and bronze industries in the USA.

Source constructionmagnet.com

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Classic Look of Metal: Cold rolled steel

Every metal roofing material and profile has its niche, including the rugged appearance of rust; reminiscent of old unpainted roofing on rural buildings, from farmhouses to barns.

As a rule, metal roofing manufacturers would rather not see rusty roofing — unless it’s by design.


Fabral supplied the 22-gauge A606 cold rolled material for the roofing at the Silver Star Condominiums in Park City, Utah ­— approximately 187,600 square feet.

“The roof represents characteristics of the mining heritage of Park City and combines the color of the metal roof with the natural environment and the contemporary mountain architecture,” says Chris Jensen of JSA Architects of Salt Lake City.

Silver Star is a luxury ski in/ski out property located slope-side at Park City Mountain Resort and adjacent to the Park City Golf Course. Silver Star offers luxury accommodations in 2-, 3- and 4-bedroom condos or townhouses and 4-, 5- and 6-bedroom cottages.



Noorda Architectural Metals of Salt Lake City handled the installation, working with JSA Architects.

The roofing — in smooth 48-inch by 120-inch flat sheet and 7/8-inch corrugated panels (39-3/4 inches of coverage) were installed over ice and water shield with #14-410 stainless steel unplated 2-inch wood grip screws with 5/16 heads and sealing washers.

Source constructionmagnet.com

Monday, May 12, 2008

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Classic look of metal: FalZinc

The material core of FalZinc, also known as Foldable Aluminum Zinc, consists of .032-inch aluminum with an alloy initially processed to accurately balance the physical properties and is then subjected to a special temperature treatment that gives the material its outstanding qualities for shaping and forming. In the Pegal procedure, patented by Corus, a zinc surface is applied to the aluminum core. FalZinc, distributed by Drexel Metals, is a superior product that is extremely installer friendly.

The result is a building product that unites ease and elegance.
FalZinc also is very environmentally friendly. In an exemplary way, FalZinc meets one of the most important ecological requirements: preservation of resources. Because of its low inherent weight and high form stability, design requirements can be met with comparatively little expenditure in terms of material and supplies.

Classic-Drexel FalZinc.jpgExcellent corrosion resistance makes FalZinc almost indestructible and guarantees many decades of complete building protection. Even under the most adverse environmental influences practically no erosion of the surface occurs. Thus, FalZinc offers a long, environmentally friendly working life. All FalZinc components are 100 percent recyclable and any FalZinc parts not usable or are surplus to requirements for extensions or alterations can be returned for recycling.

Source constructionmagnet.com

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Taking efficiency to the extreme

By the Metal Construction Association
The Metal Construction Association has recently taken steps to make architects, architectural students, universities and building owners more aware of the environmental benefits of these types of insulated metal panels.
Insulated metal panels (IMP) lead in energy conservation, recyclables and sustainability.

The Metal Construction Association, expanding the use of metal in construction through marketing, technology and education, has recently taken steps to make architects, architectural students, universities and building owners more aware of the environmental benefits of these types of insulated metal panels.

PP-LEADIN-IMPs MeTecno-MCA.jpgSustainability continues to gain importance in the building industry and focuses on the smart use of natural resources and energy efficiency as related to insulation values, fuel usage, job-site waste and recycling.
According to Scott Kriner, technical director for the MCA, “Today’s architects and building designers continue to look for ways to reduce the carbon footprint of new commercial structures. The use of IMPs for the building envelope will make a significant contribution to reducing greenhouse gas emissions related to lower energy consumption, less solid waste stream and efficient water usage.”

The single panel includes an insulated foam core, metal exterior, continuous interior metal liner, tongue-and-groove joinery, concealed clips and fasteners and factory installed joint sealants and/or gaskets. The panels can be used for the entirety of an exterior roof system or wall system and can be used in conjunction with other panels or various other materials for multi-component solutions. They are effective in any climate.

Since the panels are produced in a factory, there is reduced jobsite waste, as little or no field cutting is required, water is conserved and chemical usage is avoided during maintenance procedures. Because of the long life span and the durability of the panels, repairs are required less often than in other forms of building panels.

These metal-formed IMPs do even more for the environmental efforts than conserve energy. The skins of these insulated sandwich panels are metal, which has a very high-recycled content. The foam insulation within the panels is also recyclable. Technology already exists to recycle 100 percent of the insulation when the extended life spans of the panels eventually reach their end.

The IMPs reduce air loss, contributing to better HVAC performance, which can earn Leadership in Energy and Environmental Design energy optimization credits. IMPs can earn up to 10 points in the optimized energy performance credit. They can also contribute to LEED points for recycled content and for low-emitting materials (adhesives, sealants, paints and coatings).


About Metal Construction Association: Founded in 1983, MCA strives to expand the use of metal in construction through marketing, technology and education. MCA’s members can develop and implement both macro and micro programs and activities to promote the use of metal in construction. MCA offers its members a unique opportunity in focusing industry efforts to increase the use of metal through innovation. For more information, visit www.metalconstruction.org/imp.

Source constructionmagnet.com

Saturday, May 10, 2008

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Energy efficient products

ABC
ABC premium quality panels are made from 25-35 percent recycled materials and are 100 percent recyclable products. As an Energy Star partner, many of the company’s cool roof colors have reflectivity performance levels that meet Energy Star criteria at 2:12 pitch or greater, offering considerable energy savings. Cool metal roof colors offer energy savings significant to both economical and environmental standpoints. ABC metal roofs are energy efficient, sustainable, recyclable, durable, lightweight and cost effective.

Arkema
Arkema has produced a water-based Kynar 500 fluoropolymer resin that can be field-applied to a range of surfaces, including previously coated fluoropolymer metal roofing or siding. White coatings using this new innovative Kynar Aquatec technology offer the highest initial total solar reflectance and longest lasting retention of reflectance than any other conventional water-based roof coating. This allows a building owner to achieve the maximum energy savings from a “cool” white roof.

Atlas Roofing
Polyiso ACFoam is a Zero HCFC’s product with excellent R-values, available in 4x4 foot and 4x8-foot panels. ACFoam CrossVent polyiso insulation is a thermally efficient 4x8 foot board with 1-inch, 1-1/2-inch or 2-inch vent spacer strips separating 7/16-inch APA/TECO rated OSB from the insulation to create a cross ventilating airspace and available in thicknesses of 2.5 to 6.5 inches. ACFoam Nail Base Insulation is a polyiso insulation board bonded to 7/16-inch APA/TECO rated OSB on the topside and with a glass reinforced felt facer on the bottom. Available in 4x8 foot sheets in thicknesses of 1.5 to 4.5 inches.

Architectural Metal Systems
AMS developed CoolScape panels to meet the needs of the energy conscious, providing an attractive panel option that also maximizes efficiency and cost-savings. The panels feature vivid, fade-resistant color, incredible durability and environmentally friendly cool technology which was originally developed for the stealth aircraft in the U.S. Military. The energy-cost savings, architectural appeal, variety of profiles, texture and color, flexibility and long-term durability make CoolScape panels a popular choice for architects and building owners.

BASF Corporation
BASF is a leading global supplier of energy efficient coatings for the metal roofing industry. BASF’s industry-renowned premium coatings Ultra-Cool, Superl SP II and Vari-Cool deliver high-performance reflectivity that reduce heat levels on vital applications like metal roofing. The heat reflectivity of these coatings reduces energy and fossil fuel consumption and lessens peak energy demand and carbon footprint. These heat reflective coatings from BASF are available in a full spectrum of colors and provide exceptional color stability, durability, chemical-resistance and flexibility.

Berger Building Products
The Pro-Master line of ventilation products improves energy efficiency. Pro-Master Standard box vent, Pro-Master ridge vent, Pro-Master Highpoint Series 5 ridge vent and Pro-Master Highpoint Series 7 ridge vent all offer durable, long-lasting and cost effective solutions to increase air flow and help decrease cooling/heating costs.

Berridge Manufacturing
All Berridge colors are Energy Star rates and most qualify under LEED 2.2. The company offers a free brochure on Green, Energy-Efficient Kynar 500 Colors.

Conklin Products
The company’s line of energy efficient roofing systems begins with sprayed polyurethane. The extensive line of coatings all feature the highest reflectivity available as well as being environmentally friendly, water-based systems easy to apply with non-prorated 10- to 15-year warranties.

Cornell Corporation
Vent-Top ThermaCal ventilated roof insulation combines isocyanurate or XPS foam (customer choice) with a standard 1-inch airspace (larger airspaces available) and sheathing to create a 4x8 foot nominal panel that provides both roof insulation and sheathing ventilation to cool your roof in summer, retard ice dams in winter.

Dawn Solar
Renewable energy systems that integrate seamlessly with a building’s architecture, providing energy security and storm resistant systems that reduce building operating costs by replacing fossil fuels and electricity with solar energy. Residential and commercial systems can generate electricity along with hot water and warm air, all harvested from pre-engineered site built collectors that are installed under a broad variety of mainstream roofing and siding products.

Decra Roofing Systems
Decra offers Tile and Shake in the Energy Star-rated color, Mist Grey. With a long-standing reputation for performance, longevity, versatility and beauty, Tile and Shake now also offers energy savings. Meeting the requirements of LEED Site Selection Credit 7.2 — Heat Island Effect, the new Mist Grey color is Energy Star-compliant and meets the minimum emissivity of .9 when tested in accordance with ASTM E408.

Drexel Metals
Drexel offers Energy Star listed metal roof systems all with a minimum of solar reflectance of 25 percent. Products contribute to multiple LEED credits including recyclability, TE and solar as well. Through the Drexel Solar system, contractors can learn how to install and promote building integrated photovoltaics where energy can be produced directly from the roof system as well as thermal systems that help to heat water using the heat flux from a Drexel roof system.

Duro-Last
For buildings with aging metal roofs, the single-ply Duro-Shield metal retrofit roofing system can be installed right over an existing roof without an expensive tear-off. Duro-Shield system’s white membrane is also highly energy-efficient, reflecting up to 87 percent of the sun’s energy and delivering real utility cost savings.

EPDM Coatings
Liquid Rubber is the only liquid form of EPDM available. Liquid Roof and Rubber is nearly identical to sheet EPDM but with the advantage of being a liquid.

Englert
Englert manufacturers and distributes a wide range of standing seam metal roofing profiles coated in 26 different UltraCool colors compliant with Energy Star and U.S. Green Building Council LEED certification. Standing seam profiles from Englert can directly earn up to nine LEED credits for energy efficiency, recyclability and reuse, and can help earn an additional seven credits for water efficiency and reduction. The first LEED Platinum certified residence on the East Coast has an Englert metal roof.

ERSystems
ERSystems highly reflective top coat, Eraguard Clean Coat, resists dirt pick-up and retains 95 percent of its original reflectivity over a three-year period when applied as a thin layer (two dry mils) over standard acrylic roof coatings.

Environmentally Safe Products
Low-E Insulation is a non-toxic, polyethylene closed cell foam and aluminum design, making it Low-E resistant to the transfer of heat through convection, conduction and radiation. Low-E products are easy to work with, versatile and superior in energy efficiency making them one of the best investments for residential and commercial applications.

Fabral
The company’s Solar SSR system was designed with the highest quality, UL approved components. The flexibility and durability of these laminates make them ideal for metal roofs, where expansion, contraction and curving are considerations.

Ferro Corporation
Ferro Corporation is the leader in cool color pigments for energy efficient and solar reflective applications. Cool color pigments are used in roofing applications to reflect solar heat and make a roof cooler and more energy efficient. They are used in Energy Star, LEED, California and other regulations to mitigate Urban Heat Island and lower Energy Costs.

Garland Company
Solex eco-friendly highly reflective roof coating is formulated from Kynar Aquatec polyvinylidene fluoride, a water-based, fluoropolymer-acrylic resin and can reduce rooftop temperatures by as much as 80 degrees. The reflectance of Solex outlasts the industry standard of three years and provides a predictable energy savings with virtually no maintenance requirements.

Hunter Panels
Cool-Vent is a rigid roof insulation panel composed of polyisocyanurate foam core manufactured as a ventilated nail base roof insulation panel. This steep slope insulation board is manufactured to provide sustainable thermal insulating characteristics, while permitting air circulation within the roof assembly.

Major Industries
Reduce light pollution, optimize energy performance and improve indoor environmental quality without sacrificing quality or beauty. Guardian 275 translucent daylighting panels can be configured to fit every design and budget, with the added advantage of possible LEED credit opportunities.

Metacrylics
Metacrylics layered blanket of elastomeric acrylics encapsulate a tough stitch-bonded polyester fabric. This is applied to all overlapped corrugated metal panels and fasteners and around all penetrations and gutters. Choose from five Standard Colors, 60 Custom Colors, or select Metacrylics White, an Energy Star Certified Roof Product that keeps the roof cool in summer.

Metals USA
Metals USA Building Products’ Gerard and Allmet stone-coated steel roof systems are comprised of natural energy efficient materials that are 100 percent recyclable. The products reduce fuel consumption, thus reducing fossil fuels being burned into the atmosphere that cause pollution and smog. Metals USA offers a variety of Energy Star qualified colors that will further enhance the energy efficiencies and cost savings for home owners and businesses alike.

Metl-Span
Metl-Span III CFR is an insulated metal standing seam roof panel and is the newest innovation in all-in-one composite roof panel design combining durable interior and exterior faces with Metl-Span’s unmatched blister-free polyurethane core. Careful design parameters have enabled Metl-Span to create an incomparable roof system that is easily and quickly installed without dependence on highly skilled labor.

Met-Tile
Met-Tile’s cool roof line uses a Super Series 4800 Super Cool SMP architectural coating system. The coatings have solar reflectivity values ranging from 26 up to 67-plus percent, meeting and in some cases greatly exceeding Energy Star requirements. Met-Tile is an Energy Star partner.

Mule-Hide
The Mule-Hide product line includes single-ply membranes and accessories, plus a complete line of low-slope roofing maintenance and repair products including elastomeric acrylic coatings. Mule-Hide is an Energy Star partner, a member of the Cool Roof Rating Council, USGBC, RCMA, RRCI, GRHC, SPRI and NRCA.

MWI Components
TempShield is a safe, easy-to-use thermal insulating material that provides cost-effective high-efficiency performance for a wide range of applications. It is a technologically advanced insulation material ideal for new construction or retrofit installation in residential, commercial, industrial, metal buildings and post-frame buildings. TempShield insulation consists of one or two layers of Barrier Bubble air cellular material laminated between layers of aluminum foil to provide excellent thermal resistance.

Nationwide Chemical Coatings
Permakote Silver Seal is an elastomeric acrylic, ceramic filled, aluminum silver metallic protective coating designed for metal. It uses a latex, water-based formula that has waterproofing, insulating and reflective properties. It forms a durable rubber-like protection shield that expands and contracts with varying temperatures, and resists thermal shock.

Open Energy Corporation
SolarSave product lines are systems that combine renewable energy generation with standard building materials. The SolarSave roofing membrane line is designed for commercial and residential flat to low-slope roofs, integrating photovoltaic modules with single-ply roofing applications. The SolarSave roofing tile line is designed for residential and commercial higher pitched roofs, integrating photovoltaic tiles with many standard roofing materials.

Paradigm Shingles
Copper shingles are manufactured from 95 percent or greater recycled copper (99-plus percent pure) and premium solar reflective painted Galvalume and aluminum shingles. Painted shingles are made with finest substrates combining new and recycled metals and are coated with Energy Star compliant paints in a wide variety of standard and low gloss colors. Products can save you up to 20 percent on energy costs and are environmentally friendly from start to finish — manufactured from recycled materials, energy efficient, long lifespan and recyclable at end of use.

Polyglass USA
Polyglass provides the complete package for any roofing project with its extensive offering of high-performance reflective coatings, including its PolyPlus and PG product lines. PolyPlus 65 provides enhanced reflectivity and PG 650 provides long-lasting reflectivity and durability.

Rare Manufacturing
Shake n’ Tile steel roofs reflect and dissipate the sun's heat, which helps keep your attic cool. Cool roofs last longer than those that retain more heat; the effects of degradation from thermal expansion and contraction are reduced and well documented. Because cool roofs experience much less temperature differential during the day, expansion and contraction are nearly eliminated.

RoofMart International
Garna-Thane is a single component, liquid applied, radiant barrier. This Energy Star rated product is a PolyGlycolä elastomeric topcoat that protects roofing and wall systems monolithically.

Scandinavian Profiling Systems
The company offers its Nordman tile with Kynar 500 Ultra-Cool colors finish.

Shepherd Color Company
Shepherd specializes in high-performance ceramic colorants. These pigments enhance the value of roofing materials by imparting maximum color-fastness in extreme environments. Along with their toughness, the line of CICPs can be used in Energy Star compliant cool roofing systems — Arctic pigments. Arctic IR-reflective pigments work to decrease this heat build-up and enhance the occupants’ quality of life.

Solec-Solar Energy Corp.
LO/MIT-I radiant barrier roof coating lowers roofing surface temperatures 40-50 degrees to lower A/C loads significantly. Its low emissivity helps control expansion and contraction rates in roofing substrates, extending the roof life. The coating is low viscosity, premixed, temperature tolerant to 1,000 degrees with a low-investment, rapid payback for energy conservation.

Stonehenge Roofing Products
Stonehenge proves to be environmentally friendly, from the natural earthstone coating on its products that help protect the environment, to the built in 1-1/2-inch airspace that helps protect the home by allowing a savings of as much as 30 percent on heating and cooling a home.

STS Coatings
Heatbloc 75 is a spray applied radiant barrier designed to block more than 75 percent of the radiant heat trying to enter a home or building. It is a natural addition to the metal roofing contractor’s offering to their customers.

Texas Refinery Corp.
Aluminum Roof Coating is a non-fibered high shine asphalt coating that provides excellent reflectivity and coverage. Ideal for non-leaking metal, modified or built-up roofs, it can reduce interior temperature by as much as 26 degrees. Super Aluminum Roof Coating has reinforcing fibers to provide extra body when it’s needed.

Thermal Design
The patented Simple Saver System delivers full in-place R-values by filling the purlin cavity space with insulation and avoids compressing insulation that minimizes intended R-values. The System also provides high light reflectance that can decrease the number of required lights for the building use.

Topps Products
Topps Seal liquid applied rubber roofing system restores leaky metal roofs with an energy-efficient lightweight cap. The fully adhered, seam-free, roof surface engineered specifically for metal roofs is a time-proven reliable and economical replacement alternative. Topps Seal boasts 600 percent elongation, up to 2,750 psi tensile strength, and 0.2 perms. No tapes or mechanical fasteners are required. It contains no water so there are no wash-off worries.

United Coatings
United Coatings continues to offer innovative solutions with Kymax, a latex Kynar 500 modified roof coating. An alternative to solvent-based urethane systems, Kymax offers superior reflectivity, color stability and weatherability over new and existing roof surfaces. Kymax is Title 24 compliant and is an ideal finish coat over standing seam and corrugated metal roofs, sprayed-in-place polyurethane foam, modified bitumen, PVC, TPO, Hypalon and EPDM.

United Solar Ovonic
The Michigan company is the world leader in thin-film amorphous photovoltaics. Because of characteristics unique to the United Solar Ovonic solar cell technology, such as lightweight, ruggedness and flexibility, it is ideal as building-integrated photovoltaic roofing systems for residential and industrial customers.

Wheeling Corrugating
Every panel of the company’s painted roofing and siding is part of the SpectraCote System, a comprehensive manufacturing and paint finishing process. What makes the SpectraCote system so cool is the components that update products to meet with today’s construction and environmental standards for residential, commercial and rural building projects. The palette of SpectraCote cool colors meet or exceed the minimum requirements for Energy Star and Cool Roof certifications.

Whirlwind Building Components
Offering three different product lines, Whirlwind currently has six energy-approved colors on the agricultural/residential line, nine on the commercial/industrial line and four on the standing seam/architectural line. In addition to energy star approved colors, Whirlwind also offers cool roofing, proven to save up to 40 percent on cooling costs. Whirlwind’s feature color that meets all requirements for Title 24, Energy Star and CRRC is Cool White. Cool White has a reflectivity rating of 0.75, an emissivity rating of 0.86, and a total solar reflective index of 91.7.
Source constructionmagnet.com

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Spec It: Bermuda Panels

As one may suspect, the traditional Bermuda roofing was developed on the island of Bermuda as an effective system to aid in the collection of rain water.
The original Bermuda roof consisted of rectangular slabs of limestone, lapped over the lower row on a hip-roof frame. Mortar was applied to fill joints, so as not to allow water under the roof.

Still in Bermuda, roofing is limed to help keep the rain water clean. By law, every home on the island must collect 80 percent of the rain that falls on the roof.

Metal roofing, of course, offers a Bermuda roof profile to mimic the famous island architecture. Not only does it offer the ability to help collect rain water, but as shown in the feature on page 86, it can aid in collecting solar energy, like vertical panel metal roofing.

The look, the aesthetics, are what separate Bermuda panels from vertical panels. The horizontal lines and stepped appearance are an alternative to traditional shingled roofs or the vertical seams of standing seam or batten seam roofs.

The metal Bermuda panels, like the traditional slabs of limestone, are installed from the eaves up to the ridge.

Among the manufacturers who can provide Bermuda panels are ATAS International (Rumba Shake Bermuda), Firestone Building Products, Follansbee Steel, RHEINZINK (Quick Step), MetFab and Custom-Bilt Metals. Among the roll former manufacturers who have portable machines for the manufacturing of Bermuda panels are Berridge Manufacturing, Englert and New Tech Machinery.
Source constructionmagnet.com