Built complex

• Photo courtesy of Kodiak Roofing & Waterproofing Co., Loomis, Calif.
• Photo courtesy of Kodiak Roofing & Waterproofing Co., Loomis, Calif.
• Photo courtesy of Kodiak Roofing & Waterproofing Co., Loomis, Calif.

The Elk Grove Community Services District (CSD), Elk Grove, Calif., is an independent local government agency that provides a variety of services for residents of Elk Grove and neighboring areas. The district spans about 106 square miles (275 km²) and operates more than 50 parks and six fire stations, catering to a population of more than 90,000. With CSD's deep community involvement, the agency constantly must work to provide for the community and keep its residents happy.

It surely will be doing so with its new $17.5 million Barbara Morse Wackford Community and Aquatic Complex. Situated on a 9-acre (4-hectare) site, the mixed-use complex boasts a gymnasium, teen center and three pools, among other things.

Kodiak Roofing & Waterproofing Co., Loomis, Calif., was chosen to install standing-seam metal and single-ply roof systems on the single-story, 43,000-square-foot (3995-m²) complex.

Shaping up

Kodiak Roofing & Waterproofing installed a metal roof system that covers a layer of polyisocyanurate roof insulation fastened to a structural metal deck. Clips, bearing plates and screws were used to fasten the metal roofing materials through the rigid insulation board and into the metal deck. An AEP-Span standing-seam metal roof system with 17-inch- (432-mm-) wide Design Span metal panels was used.

One of the most unique aspects of the new roof system was the installation of a large radius metal roof over the east end of the community center building.

"A steel frame substructure required us to create the cone-shaped metal roof on-site," says Jeff Russell, project manager for Rudolph and Sletten General Contractors, Foster City, Calif. "The roof is like a metal skin that goes over the substructure."

Unique methods were used to create the roof system's cone shape.

"The curving, conical roof was a challenge because the flat, structural-steel metal deck doesn't bend well," Russell says. "Our project superintendent came up with a creative framing solution by using metal studs and clips of different heights like spokes of a wheel to create the cone effect."

"The design and installation of the conical roof structure was done well, which made it easier for us to lay out, fabricate and install the tapered panels," says David Ford, project manager for Kodiak Roofing & Waterproofing.

The cone-shaped roof measures 55 feet (17 m) across, and the top is 30 feet (9 m) high. The roof has a 7-in-12 (30-degree) slope.

Details, details

Kodiak Roofing & Waterproofing used two types of standing-seam panels for the installation—tapered Select Seam® on the cone-shaped section of the roof and Design Span® on the rest of the roof.

"Select Seam is AEP-Span's version of a 'T-panel' and commonly is used for its versatility when installing cone-shaped and radius roofs," Ford says. "At the point where the community center building transitions from a straight sloped roof to a conical shape, the last seam of the Design Span panel was modified to mimic a Select Seam panel. This allowed the first tapered panel to be joined using a Select Seam clip and batten, which made it a smooth transition."

The entire south side of the gymnasium roof was equipped with solar panels that were attached to the roof panels with S-5!™ clamps, which allow attachment to the roof system without penetrating the metal roof. Kodiak Roofing & Waterproofing worked with AEP-Span to design the metal roof system so it could support the structural weight load of the solar panel system.

"The manufacturer designed how many drag-load screws were needed and what screw sizes needed to be installed at each panel at the top so when all the weight of the solar panel system is pulling on the panel, it does not pull the panels off the roof," Russell says. "We also had to work with the structural engineer so the screws had something to screw into to anchor each panel."

Because the complex was a structural steel building, the roofing contractor faced some challenges.

"When you put up a structural steel building, there are tolerances allowed in the structural steel that are not allowed with a finished product like a metal roof system," Russell says. "There was a customized expansion joint in the body of the metal roofing that was a bit of a challenge because the expansion joint intersected two valleys, a ridge, gutter system and portion of the conical roof. Kodiak Roofing & Waterproofing solved it quite well by designing custom transition flashings with watertight joints using butyl tape sealant. The overall slope of the roof was fairly steep, so just the installation was tough."

Although there were challenges and the project faced weather delays such as rain and wind, production remained on track.

"Working during the winter always is a scheduling challenge," Ford says. "We had confidence in our project superintendent's abilities to schedule the crews when the weather window permitted us to work on the project."

The job site fortunately was situated near a major highway and in an accessible location, so there were no problems getting materials to the job site.

The safety aspects of the project also went smoothly, because precautions were taken to fit the complexity of the project.

To safely work on the roof, Kodiak Roofing & Waterproofing used an anchoring system that was screwed into the metal deck with a steel clamp on which to tie off. The anchors used were low profile and "disposable," so workers could install over them without interrupting the roof system. Workers' safety harnesses were attached to the steel clamp.

"Workers had to tie off in conditions where the eave height was greater than 15 feet (5 m), at an 8-in-12 (34-degree) slope or if there was inclement weather," Ford says. "Roofing workers used full-body harnesses with lanyards and lifelines to secure themselves."

A satisfied public

After all the hard work and careful planning, it seems CSD has continued to keep its residents happy.

"This is an attractive roof system and has received a lot of positive feedback from the community," Russell says.

Krista Reisdorf is associate editor of Professional Roofing magazine.

Project name: Barbara Morse Wackford Community and Aquatic Complex
Project location: Elk Grove, Calif.
Project duration: November 2003-June 2004
Roof system type: Standing-seam metal and single-ply
Roofing contractor: Kodiak Roofing & Waterproofing Co., Loomis, Calif.
Roofing manufacturer: AEP-Span, Dallas, and Sarnafil Inc., Canton, Mass.