Photo courtesy of Louisiana's Office of Facility Planning and Control
Photo courtesy of Louisiana's Office of Facility Planning and Control
Photo courtesy of Bert Rhine Productions, San Diego
Photo courtesy of Bert Rhine Productions, San Diego
Photo courtesy of Brazos Urethane
Photo courtesy of Brazos Urethane
Photo courtesy of Bert Rhine Productions, San Diego
The Louisiana Superdome in New Orleans has been an important part of sports history. Besides hosting the New Orleans Bowl, it has hosted nine Super Bowls—currently more than any other sports facility.
However, during August 2005, the Superdome became a part of a different type of history when Hurricane Katrina ravaged New Orleans, severely damaging the stadium, which also became a temporary shelter for tens of thousands of hurricane evacuees.
The hurricane ripped two holes in the Superdome's roof—each about 4 feet wide and 100 feet long—and peeled about 80 percent of the EPDM membrane off the roof.
Repairing roof damage for a New Orleans institution required hard work and patience. Brazos Urethane Inc., Texas City, Texas, was willing to take on the task.
Complete overhaul
The Superdome's original 422,000-square-foot roof system consisted of a steel deck that varied from 18 gauge to 20 gauge, 2-inch-thick polyisocyanurate board insulation and 60-mil-thick EPDM membrane.
Brazos Urethane was asked to remove the roof system and metal deck, replace the deck and install a 3-inch-thick spray polyurethane foam- (SPF-) based roof system with a urethane coating system.
"During the tear-off process, we cut the steel deck between the purlins and girts," says Wally Scoggins, president of Brazos Urethane. "We then chiseled the welds off the steel structure."
The company installed BaySystems NorthAmerica LLC (BSNA) Aquapoxy primer and BSNA 100 acrylic primer.
"New metal panels were primed on the floor of the Superdome before being installed on the roof," Scoggins says. "The flutes were filled with foam; then, the panels were reprimed and sent to the roof after curing."
Lifting materials to the roof was not easy.
"No crane on the planet could reach from the street to the center of the dome," Scoggins says. "We used small roof hoists mounted on the roof to lift everything. We hoisted four panels at once, with each lift taking about seven minutes."
The shape of the roof posed a challenge, as well.
"The dome-shaped roof was not a problem when installing the SPF, but the dome made it extremely challenging to install the new 16-gauge deck and keep it completely watertight because the panels are flat and the dome is curved," Scoggins says.
The roofing workers were completely tied off during the project, which employed 125 workers during its peak time. Still, safety was a major concern.
"We had eight official visits from the Occupational Safety and Health Administration because of the high-profile aspect of the project, as well as the danger involved," Scoggins says. "We had pressure from everyone who was counting on us to finish on time and not allow any leaks during construction."
Back in the game
The project's challenges made it special.
"The schedule and steepness of the roof were unique," Scoggins says. "There was demolition, framing, drywall, painting, electrical work, new scoreboards, a new field—everything was being replaced as we were removing the roof.
"We had to complete the roofing work and fully maintain watertightness during the project so the other contractors could complete their work in time for the New Orleans Saints-Atlanta Falcons NFL football game Sept. 25 that would reopen the Superdome," he continues.
For this reason, timeliness was important.
"We had to finish everything and move our office, equipment and tools off the floor so the field contractor could install the artificial turf and paint logos on the field," Scoggins says.
The job would not have been completed so efficiently if Brazos Urethane had not received help, Scoggins says.
"Insulated Roofing Contractors, Louisville, Ky., helped us install the foam and coating system, and East Iowa Deck Support Inc., Burr Ridge, Ill., demolished the deck and installed the new deck," he says. "Both were a great help in completing the project 32 days early.
"The Superdome roof replacement is the largest roofing project we ever have done," he continues. "We were completely prepared for every event."
And thanks to the work of all involved, the Superdome was prepared for its big event. It reopened and hosted the New Orleans Saints-Atlanta Falcons NFL football game, resurrecting not only a New Orleans institution, but also, perhaps, the hope for a new beginning.
Krista Reisdorf is managing editor of Professional Roofing magazine.
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