A successful recovery

• Photo courtesy of B.T. Lakeside Roofing Inc., Addison, Ill.
• Photo courtesy of B.T. Lakeside Roofing Inc., Addison, Ill.
• Photo courtesy of B.T. Lakeside Roofing Inc., Addison, Ill.
• Photo courtesy of B.T. Lakeside Roofing Inc., Addison, Ill.
• Photo courtesy of B.T. Lakeside Roofing Inc., Addison, Ill.

Asphalt and coal-tar pitch have been used in the roofing industry for decades. However, their use has become a controversial topic for roofing contractors as government agencies have raised health concerns with regard to asphalt fumes. Although coal-tar emissions are regulated by the Occupational Safety and Health Administration (OSHA), there has been no proof of health hazards from asphalt fume exposure, but awareness of the issue has become heightened.

Constantly striving to stay on the edge of the newest technological advances, as well as maintain health and safety, the roofing industry has introduced ways to address asphalt fume concerns. One method has been the use of fume recovery systems, which filter and eliminate most fumes and odor.

B.T. Lakeside Roofing Inc., Addison, Ill., was able to employ an FRS 800 fume recovery system for the first time while reroofing River Place Condominiums, Naperville, Ill.

The extra mile

B.T. Lakeside Roofing discovered the two-building condominium project through George Etter, the chief building engineer for the River Place Condominium Association. Etter, who had used the roofing company for a project in a different location in the past, helped get B.T. Lakeside Roofing on the bidders list. The condominium project required the use of asphalt and coal-tar pitch.

"We were asked to bid a complete tear-off of the existing roof systems," says Tom Wykle, president and owner of B.T. Lakeside Roofing. "The original roof systems were each 25,000 square feet (2323 m²) with 5 1/2-inch- (140-mm-) thick expanded polystyrene insulation and ballasted EPDM over poured-in-place concrete decks."

The roof systems had to be torn off because they were failing after 18 years and started to leak. The roof consultant advised the company to switch from EPDM to a coal-tar-pitch roof system.

The project also required the use of a fume recovery system for asphalt and coal-tar fumes. B.T. Lakeside Roofing rented a fume recovery system, and it was the company's first time using such a system on a project.

"It was interesting and new to our company," Wykle says. "The system looked like something from 'Mad Maxx Beyond Thunderdome.' But it made the job more appealing for the residents of the condominiums, as well as for the ground man."

Rising to the challenge

The company installed two layers of No. 15 organic asphalt felt as a vapor retarder and temporary roofs on the two condominium buildings.

"We installed four-ply Koppers Commercial Roofing coal-tar-pitch and gravel roof systems," Wykle says. "We installed two layers of felt set in hot asphalt over the concrete decks, as well as 1/8-in-12 (0.6-degree) slope of Koppers tapered polyisocyanurate insulation and Koppers 1-inch- (25-mm-) thick perlite. The roofs also had many projections, so we installed wood blocking around each projection, which took a long time."

The project took three weeks longer than expected.

"There were a lot of special details that needed to be addressed," Wykle says. "We had a lot of equipment to deal with—two kettles, a tanker and fume recovery system. Plus, this was our first job with the fume recovery system. The filters need to be changed at certain intervals but also at different time frames depending on the filter type."

The company also met problems when trying to get materials for the project.

"The felt gave us some problems because no suppliers in Chicago stocked it," Wykle says. "It took an additional two weeks, but we ended up getting it from Georgia-Pacific Corp."

Other issues were present, as well. For safety reasons, B.T. Lakeside Roofing had to keep the kettle away from trees.

"After our equipment had been set up, we had to disconnect the pipes and move all equipment back about 8 feet (2.4 m)," Wykle says. "The branches of the trees needed to be tied back to keep them from catching on fire."

Various other challenges slowed the process.

"There were technical aspects of the job that needed special attention, which slowed the process," Wykle says. "Each projection had a galvanized pitch dam at the base, wood blocking and insulation, as well as the four-ply tar felts and a custom stainless-steel pitch pan, which was filled with sealer and capped off with a custom stainless-steel umbrella cover.

"Once we got a handle on a method that would address these details, the second of the two buildings went more quickly. The roof consultant also would slow the flow of the workday by questioning numerous procedures and details. In addition, our tanker broke down; we finally ended up using our kettles instead of nursing the tanker."

Safety first

As mentioned, especially when working with kettles and tankers, safety was an important issue.

"This was a high-profile project because the property is visible from the street and located along the popular Naperville Riverwalk area," Wykle says. "The two condominium buildings are highly populated, which increased the chance for the Occupational Safety and Health Administration, a roof consulting firm or other inquiring minds to stop by. We took great care in the setup of this job site.

"We have worked with the safety firm Adams Safety Management Services LLC, Oak Brook, Ill., for the past five years, and it assisted in evaluating the site," Wykle continues. "The perimeter edges all were flagged. We fenced off the chute area and covered the parking lot under the tanker and kettle in case there were tar spills. The kettle and tanker workers wore personal protective equipment. The kettle and tanker were placed in a spot that did not create a fire hazard for the trees. Ramps and chute areas on the roof were prepared with the utmost care, and all ground equipment was fenced in to discourage unauthorized visitors."

A learning experience

Although the conspicuous aspect of the project added some pressure, Wykle appreciates it and says it was rewarding.

"The high-profile area, neighborhood, job size and specifications of this project took our company to a new level," he says.

The fume recovery system, which played a prominent role in the project, made the job rewarding, as well.

"Our company never had used this system before," Wykle says. "There was a learning curve associated with the fume recovery system as far as the setup and maintenance of the machine. We had fewer complaints about the odor of the job from residents. There also was a lot of curiosity with regard to the appearance of the system, so it drew attention to the job."

In the end, use of the fume recovery system was educational for the roofing workers and effective for the project.

"We learned that people could have this type of roof system without the annoyance of strong fumes," Wykle says. "We all learned a new aspect of roofing. I would say the fume recovery system put a big spin on this job.

"I think once we got over the initial setup," he continues, "we were proud to have tried something new and succeeded in completing a beautiful roof system for the owners of the property."

Krista Reisdorf is associate editor of Professional Roofing magazine.

Project name: River Place Condominiums

Project location: Naperville, Ill.

Project duration: July 1, 2004-Oct. 29, 2004

Roof system type: Coal-tar pitch

Roofing contractor: B.T. Lakeside Roofing Inc., Addison, Ill.

Roofing manufacturer: Koppers Commercial Roofing, Pittsburgh