Photo courtesy of Red Pointe Roofing, Orange, Calif.
Photo courtesy of Alfred State University of New York, Alfred.
Photo courtesy of Alfred State University of New York, Alfred.
Photo courtesy of Alfred State University of New York, Alfred.
Photo courtesy of U.S. Department of Energy Solar Decathlon.
Photo courtesy of Alfred State University of New York, Alfred.
Photo courtesy of Upstate Roofing and Painting, Rochester, N.Y.
Photo courtesy of Alfred State University of New York, Alfred.
The U.S. Department of Energy Solar Decathlon is a program that challenges collegiate teams to design, build and operate solar-powered houses that are cost-effective, energy-efficient and aesthetically pleasing, according to www.solardecathlon.gov.
Since its inception in 2002, the Solar Decathlon has achieved worldwide success by involving 130 collegiate teams, which has positively affected nearly 20,000 participants.
When a team of students from Alfred State—State University of New York (SUNY) College of Technology, a small college of technology in Alfred, N.Y., and Alfred University, a small comprehensive university in Alfred, was selected to compete in the 2015 Solar Decathlon Oct. 8-18 in Irvine, Calif., NRCA member Upstate Roofing and Painting, Rochester, N.Y., provided training for the daunting project.
However, the team, which already would be competing against larger schools, would be presented with an additional challenge after it left New York for the West Coast, and Upstate Roofing and Painting was able to call on an NRCA member in California for help.
The project
The purpose of the Solar Decathlon is to increase the use of energy-efficient products and design methods by educating students and the public about financial and environmental benefits of these products and designs; demonstrating the comfort and affordability of energy-efficient homes; and offering student participants training that helps prepare them for the clean energy workforce.
Participating teams spend almost two years designing and constructing energy-efficient houses powered by solar energy. The winning team's house must be affordable, attractive and easy to live in; maintain comfortable and healthy indoor environmental conditions; supply energy for cooking, cleaning, entertainment and commuting; provide adequate hot water; and produce as much or more energy than it consumes. Twenty-nine universities from five countries formed 17 teams that competed in the 2015 Solar Decathlon.
Although Alfred State and Alfred University are separate entities, Alfred State originally was part of Alfred University as a New York State statutory college but joined SUNY in 1948. Alfred State and Alfred University decided to work together on a 2015 project—called the Alf House—after working together on a project for the 2013 China Solar Decathlon, where the team earned first place in the Energy Balance contest (teams compete in 10 contests for the Solar Decathlon).
Alfred State has a full set of construction-related programs that include architecture; mechanical engineering technology; building trades; electrical construction and maintenance electrician; and air conditioning and heating technology—all of which were involved with the project. Alfred University's mechanical engineering and renewable energy engineering programs were involved with the project's technical aspects.
The goal of the team's design was to build a 900-square-foot modular zero-energy home that would appeal to middle-class families in rural western New York. The home included traditional wood frame construction with structural insulated panels; a photovoltaic grid-tie system; a solar hot water system; and high-efficiency appliances, materials and systems.
The training
Dave Pastore, CEO of Upstate Roofing and Painting, and Bob Morgan, chief operating officer of Upstate Roofing and Painting, are alumni of Alfred State's architecture program, and Morgan also currently is a member of the Alfred State Building Trades Advisory Board.
"When we learned of this project, we wanted to see how Upstate Roofing and Painting could help," Morgan says.
The company offered to provide hands-on training for the single-ply TPO roof system the students chose to design and install. Because the house would be built on Alfred State's Wellsville, N.Y., campus and then shipped to California, it needed to be constructed so it could be disassembled. It was decided the house would be built in three 10- by 10- by 30-foot sections for transporting.
"Tackling the TPO roof system, which included tapered insulation, was a challenge because it could not be permanently installed in New York," Morgan says.
Morgan approached the school with the idea of having an eight-hour training day on campus.
"The idea was to lay out the roof like a puzzle without attaching anything permanently," Morgan says.
Dan Pastore, superintendent for Upstate Roofing and Painting, and Brock Alexander, a manufacturer's representative for Carlisle SynTec Systems, Carlisle, Pa., led the training. They directed the students regarding how to pre-cut the membrane, tapers and other components, and labeled everything for easy shipping and installation in California.
"The students installed wood blocking at the edges to meet the insulation height needs, cut out the blocking to accommodate the future installation of the scuppers, and laid out shop-fabricated fascia metal to finish off the edges," Morgan says.
Additionally, the Alfred team was one of the few teams in the competition that relied on students to construct the homes—most teams had help from contractors during various phases of construction.
"We were the only school I know of that had students being trained in the trades," says Craig R. Clark, executive director and dean of the School of Applied Technology for Alfred State. "Most participants were architectural and engineering students, and many were graduate students. These students had little to no skilled trades training."
The project goal was to keep costs under $250,000, and most of the products for construction were donated or discounted; 100 percent of the roofing materials were donated by B&L Wholesale, Rochester, and Carlisle SynTec Systems. Upstate Roofing and Painting provided the training and miscellaneous supplies.
"The training was a success," Morgan says. "However, the biggest challenge was how these students were going to put all this together permanently—and to spec—once they got to California."
Making a call
Because constructing the Alf House primarily relied on students, the team still required guidance for the permanent roof system installation in California.
"Certainly they did not have the specialized tools or experience needed to put this roof together on their own in California," Morgan says.
So Morgan reached out to his friend and NRCA Director Aaron Martin, president of Red Pointe Roofing, Orange, Calif.
"I asked Aaron whether he would be willing to provide a crew truck with an array of tools and some roofing professionals for guidance," Morgan says.
Through NRCA's Young Contractors Committee's Trade School Task Force, Martin already was familiar with Morgan's involvement with Alfred State regarding promoting their roofing curriculum. He also was impressed by the program Alfred State offers, which includes broad construction trade disciplines and hands-on instruction.
So when Morgan called upon Martin to help, Martin didn't hesitate.
"Aaron was on board and personally made three trips to the project site to check on things and provide guidance once the Alfred team arrived," Morgan says.
The Alfred team was in contact with Martin a week before the roof system was scheduled to be installed.
"Martin and one of his employees visited the site the day before installation began and gave the students a refresher on the seaming procedures," says George Richardson, chairman of the Building Trades School of Applied Technology for Alfred State. "He also was there during the installation to make sure there were no problems. This proved invaluable because the day after the roof system was installed, there were heavy rains and no roof leaks."
Martin says although his company helped with the project, the students did the hard work.
"Red Pointe Roofing really had little involvement in the Solar Decathlon construction because the students were already trained by Upstate Roofing and Painting regarding the roof system applications," Martin says. "We provided key industry-specific equipment, some detailing materials and a few trade pointers from Ricardo Oropeza, a journeyman technician with Red Pointe Roofing. All the installation work was eagerly completed by the students themselves!"
Martin's company offered guidance as the Alfred team installed a TPO membrane system over tapered rigid roof insulation at the low-slope roof areas.
"We found ourselves checking in on the project periodically, in part to make ourselves available for any roofing-related questions or direction, but also because of our interest in observing the quick construction—the build team had about 10 days to erect a 900-square-foot fully operating residence," Martin says.
More than 100 students from Alfred State and Alfred University were involved with the project, including 18 students who constructed the home in California.
"The team that put the home together in California included 17 Alfred State students in building trades, air conditioning and heating technology, and electrical construction and maintenance electrician programs; an Alfred University student; two Alfred State alumni in the Northeast Regional Council of Carpenters; and two Alfred State faculty," Clark says.
The Alf House finished 11th overall in the competition and took third place in the Comfort Zone contest and the Affordability contest, which were the two categories the team especially focused on during the contest.
Promoting opportunities
While on an NRCA-related trip to San Diego, Morgan and his wife and daughter took a small detour so they could visit the finished Alf House on the first day of the competition.
"It was an amazing task these students tackled," Morgan says. "It was a special moment for me to see how proud the students were to show off their efforts to those who attended the competition."
Pastore agrees, saying the students' energy during the training in New York was infectious.
"It was a rewarding experience to be able to help with such a unique project," Pastore says. "I was energized to see how interested the students were with learning a portion of the roofing trade."
Martin says it was a special experience.
"The Alfred team did a great job with both roof system installations," Martin says. "Red Pointe Roofing was happy to be a small participant in this project and would like to support the program again in the future."
The Alfred team appreciated the help it received from the roofing companies.
"Alfred State and the Alfred team want to thank Bob Morgan and everyone who helped us during this phase of the project that allowed students to learn about installation and roofing materials in a hands-on way," Clark says.
Morgan appreciated the program offered some insight into career opportunities in roofing.
"Roofing contractors are not afforded many opportunities to expose college students to our trade," he says. "These students attend college to pursue a degree that will allow them to work with their hands in the field. This was a great project to show the students that a career in roofing is something to consider."
Krista Berns is Professional Roofing's director of online communications.
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