A perfect pair

• Photo courtesy of Pfister Energy, Paterson, N.J.
• Photo courtesy of Pfister Energy, Paterson, N.J.
• Photo courtesy of Pfister Energy, Paterson, N.J.
• Photo courtesy of Pfister Energy, Paterson, N.J.
• Photo courtesy of Pfister Energy, Paterson, N.J.
• Photo courtesy of Pfister Energy, Paterson, N.J.

Valley National Bank, Wayne, N.J., has been progressive and energy-conscious when making changes to its corporate headquarters building. Several energy-efficient projects were performed at the corporate headquarters during the past few years, including the installation of energy-efficient lighting and heating, ventilating and air-conditioning retrofits.

So when the bank needed a new roof system, energy efficiency was an important factor.

"Scott Watkowski, vice president of facilities at Valley National Bank, was interested in pursuing renewable energy and solar projects for the bank," says Wayne Pfisterer, president of Pfister Energy, Paterson, N.J. "The bank's headquarters also needed a new roof system. Valley National Bank's lighting retrofit contractor referred Pfister Energy for a solar project and new roof system installation."

The original roof system on the Valley National Bank headquarters was about 15 years old and had begun to fail. The 22,425-square-foot (2,083-m²) roof system consisted of a steel deck, 2- to 5-inch- (51- to 127-mm-) thick tapered insulation and a ballasted EPDM membrane. The company had to remove the existing ballast before installing the new roof system.

"Pfister Energy vacuumed the existing ballast from the roof, which was recycled as landscape stone at various Valley National Bank locations," Pfisterer says. "Leaving temporary ballast in place to protect the building interior during construction, we removed the remaining roof ?system as the new roof system and solar panels were installed."

Best of both worlds

Pfister Energy was asked to provide a new roof system that could accommodate a solar array and suggested a unique solar-integrated panel roof system that combined a Soprema two-ply SBS-modified bitumen roof system and flexible, thin film photovoltaic laminate panels from Uni-Solar, Auburn Hills, Mich. It was the first project of this nature for Pfister Energy; the company previously had conceived the idea of performing such a project, and the Valley National Bank project implemented that idea.

"The owner was delighted we could provide a turnkey solar and roofing solution that offered several benefits to Valley National Bank," Pfisterer says. "We promised completion of the roof system and solar panels at the same time, a single point of contact during design and construction, one warranty, and reduced construction time and costs."

As installation began, Pfister Energy replaced wet or damaged insulation with new materials. For the base material, 1?2-inch- (13-mm-) thick primed DensDeck® was mechanically fastened over the existing tapered insulation.

The two-ply Soprema SBS-modified bitumen roof system was installed in a two-phase process, and Pfisterer says the placement of every roll was critical to the design and layout of the solar panel system.

"First, the Soprema roof system was laid out roll by roll in AutoCAD™ in a pattern that would best accommodate the existing roof and installation of the Uni-Solar photovoltaic system," he says. "Once the design was complete, the Soprema roofing material was installed in exact accordance with the engineered pattern."

Pfister Energy installed a base-ply membrane of Sopralene Flam 180 and second cap-ply membrane of polyester-reinforced Sopralene Flam 180 FR GR White.

After the roof system was installed and final inspection was completed, a cold epoxy resin was applied and the Uni-Solar photovoltaic panels were adhered directly to the roofing material.

Pfister Energy's boom truck hauled materials and equipment up to the roof of the five-story building.

The company used two crews—a roofing crew of about 12 members and solar-installation team of about seven members—with some crossover during installation of the roof system and solar panel system.

Pace and precision

The five-month project included anticipated delays, such as utility inspections, state inspections and electrical inspections. However, a more significant obstacle required extra attention.

"The biggest challenge was the fast-drying two-part epoxy used to adhere the Uni-Solar photovoltaic panels to the Soprema roof system," Pfisterer says. "Because of the hot July weather, the epoxy was drying faster than estimated. By keeping the two adhesive components submerged in ice baths near the glue site, we were able to keep their temperatures low.

"However, once the adhesive was applied to the panel, we also had to be precise with positioning the photovoltaic panels on the roof as they could not be moved at all once placed," he continues. "This precise positioning was critical; each solar panel's exact location had been designed in accordance with the engineered layout of the Soprema roofing material."

Reaping the benefits

The project's unique installation made Pfister Energy proud.

"This integrated roof and photovoltaic solar system is the first installation of its kind," Pfisterer says. "Both Uni-Solar and Soprema engineering teams were supportive of the proposed Pfister Energy design and installation, and Valley National Bank was instrumental in promoting cutting-edge technology that saved the bank money and time. This project demonstrates how roofing and solar technology can be applied effectively at the same time, as well as offer time and cost savings and a single warranty.

"And the bank knows that if there ever is a problem with the roof or panels or both, there won't be any finger-pointing between the manufacturers and the installer," he continues. "We all work as one."

Pfisterer also says energy savings could be significant for the building.

"Although energy savings can depend on factors such as the energy consumption of the building or the light shed on the building each year, I think it is fair to say the roof system will save 20 percent of annual electric energy consumption," he says.

Watkowski is happy with the energy savings that will result from the project.

"We not only are reducing our electricity costs, we actually are earning New Jersey Renewable Energy Certificates that generate income for the bank," he says. "With the produced power and state credits, our integrated solar roof system will pay for itself in less than eight years. With a roof system life expectancy of 30 years, we're looking forward to a quality roof that protects our building and generates returns for 20 years to 25 years."

And sometimes, the best reward simply is a job well done.

"Besides being the first company to promote and install this type of integrated roof and solar system, it was rewarding to see the solar system turn on and run without any problems," Pfisterer says. "The roof works, too!"

Krista Reisdorf is managing editor of Professional Roofing magazine.

Project name: Valley National Bank
Project location: Wayne, N.J.
Project duration: March 2005-July 2005
Roof system type: Solar-integrated panel roof system
Roofing contractor: Pfister Energy, Paterson, N.J.
Roofing manufacturer: Soprema Inc., Wadsworth, Ohio, and Uni-Solar, Auburn Hills, Mich.