A dome in Macomb

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Since 1992, Clinton-Macomb Public Library has been serving residents of Macomb, Mich. A member of the Suburban Library Cooperative, Clinton-Macomb Public Library is part of a community that provides services to the public through 27 libraries in the northern Detroit area.

In July 2001, the library’s north branch opened. Twenty years later, in August 2021, the original building closed. And in September 2021, the library reopened in a newly constructed facility. Located within Macomb Town Center, the library’s north branch provides quality programs for children and adults and offers the latest in books, DVDs, CDs and more.

William Molnar Roofing Co. Inc., Brownstown, Mich., was invited by the project’s construction manager, McCarthy & Smith Inc., Farmington Hills, Mich., to bid on the roofing work and subsequently was selected to install an EPDM low-slope roof system and copper dome.

EPDM

The William Molnar Roofing crew began work on the roofing project in August 2020. Three low-slope roof decks consisted of 18,500 square feet of structurally sloped steel, 4,700 square feet of flat steel and 2,000 square feet of flat double-layer tongue-and-groove wood planks.

On the structurally sloped steel deck, workers mechanically fastened two layers of Carlisle® InsulBase® 2½-inch-thick, 4- by 8-foot 25-psi polyisocyanurate insulation boards using Carlisle HP-X Fasteners. To divert water to drains, workers adhered 4- by 4-foot 25-psi polyisocyanurate insulation tapered ½ of an inch per foot using Carlisle Flexible FAST™ Adhesive. Next, workers adhered ½-inch-thick, 4- by 4-foot Georgia-Pacific DensDeck® Prime Roof Boards using Carlisle Flexible FAST Adhesive followed by Carlisle Sure-Seal 90-mil-thick EPDM adhered with Carlisle CAV-GRIP III Adhesive/Primer.

On the flat steel and wood plank decks, crew members mechanically fastened one layer of Carlisle Insulbase 2½-inch-thick, 4- by 8-foot 25-psi polyisocyanurate insulation boards using Carlisle HP-X Fasteners. Then, workers adhered 4- by 4-foot 25-psi polyisocyanurate insulation tapered ½ of an inch per foot using Carlisle Flexible FAST Adhesive. Next, workers adhered ½-inch-thick, 4- by 4-foot Georgia-Pacific DensDeck Prime Roof Boards using Carlisle Flexible FAST Adhesive followed by Carlisle Sure-Seal 90-mil-thick EPDM adhered with Carlisle CAV-GRIP III Adhesive/Primer.

All the low-slope roofing work had to be completed during winter months, requiring workers to remove snow when necessary. Materials were stored inside the building as well as in “hot boxes” to prevent freezing.

Copper dome

The biggest challenge workers faced was working on a 2,900-square-foot dome atop a third-story structure that was above the newly installed EPDM membrane. Workers had to use extra care when staging and working in this area to avoid puncturing or tearing the membrane.

Additionally, the dome’s shape made access difficult.

“With an approximate 44-foot diameter at the base of the dome at an elevation of nearly 30 feet, getting to the work face required us to fabricate a task-specific, curved ladder,” William Molnar Jr., president of William Molnar Roofing, explains. “This ladder connected to a central pin. The base of the ladder had rubber tire wheels fixed to it so it could revolve around the dome and allow our tied-off workers to install the copper shingles without applying stress to the installed surfaces.”

On the dome’s plywood roof deck, workers laid self-adhering Grace Ice & Water Shield® HT underlayment followed by mechanically fastening 20-ounce copper shingles custom-fabricated off-site by William Molnar Roofing craftsmen. On the areas with a slope less than 3:12, workers soldered the shingles.

“There is a certain complexity to the compound curvature of any dome,” Molnar says. “There is no standard size for shingles when installing on this type of construction. Computer modeling helped us get close dimensions for bidding and design, but as the installation process continued, physical measuring and layout was necessary.”

To ensure there were enough shingles to keep pace with the workers installing the copper, two fabrication shifts worked to create the shingles as the dimensions were measured and called in to the fabrication department.

The project also faced a shortage of workers.

“We had other projects we were committed to in addition to this project,” Molnar says. “Because of limited manpower, we had to increase work hours and get ‘all hands on deck.’ This included administrative staff and management helping out however they could to support the installation teams.”

To help alleviate a shortage of workers on future projects, the ratio of roofing workers to apprentices was 1:1.

“The opportunity to challenge our young workforce and watch them use their skills and independent critical thinking to solve problems in real time was the most rewarding part of the project,” Molnar says.

Quite a feat

In September 2021, the William Molnar Roofing crew completed work on the Clinton-Macomb Public Library—North Branch. Despite labor being in short supply, the team completed the project in time for the library’s opening.

“Seeing the project complete and hearing members of the community complimenting the finished project brings satisfaction to anyone who has participated in such an endeavor,” Molnar says. “Much credit is due to the whole building team and various trades that worked on the project. Building such a beautiful building with form and function while overcoming all the challenges during a pandemic is quite a feat. The entire construction team should be proud.” 

CHRYSTINE ELLE HANUS is Professional Roofing's associate editor and an NRCA director of communications.

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