Close-up

Construction of the Uline Distribution Center in Pleasant Prairie, Wis., was completed during the summer of 2009. M.M. Schranz Roofing Inc., Milwaukee, performed the roofing work for the project.

"We were asked to furnish and install an EPDM roof system and architectural sheet-metal flashing trim on the new 1.72 million-square-foot distribution center," says Chris Busalacchi, vice president of M.M. Schranz Roofing.

M.M. Schranz Roofing installed one layer of Firestone Building Products ISO 95+ 1 1/2-inch-thick polyisocyanurate board insulation loose-laid over a structural metal roof deck; a 2 1/2-inch-thick layer of AHC Foam Technologies Type II Foam-Control® EPS insulation; and Firestone Building Products RubberGard™ EPDM roof system.

The company's roofing work also included a concrete walkway, perimeter sheet-metal flashing and 245 skylights that provide natural light and reduce the facility's electrical costs.

Safety issues were addressed during the project.

"The general contractor had a 6-inch tie-off rule in effect and would not permit use of the 'safety monitor system' currently allowed by the Occupational Safety and Health Administration," Busalacchi says. "We erected a Fall-Ban Cableguard Fall Protection System, which allowed our workers to install the roof system without risk of falling. The workers setting up and breaking down the fall-protection system, as well as workers installing perimeter sheet-metal trim, were tied-off to an AES Raptor R1000™ Mobile Fall Protection System."

Additionally, for safety reasons, the skylights were not constructed until the roof system installation was finished.

"The openings for the 245 skylights were not made until the roof system was completed, which eliminated fall hazards during roof system installation," Busalacchi says. "The AES Raptor R1000 Mobile Fall Protection System was used while cutting the openings and installing the skylights."

Busalacchi says the significant amount of materials used during the project posed a challenge.

"The biggest challenge probably was coordinating the large amount of materials (about 400 truckloads) and making sure we had enough materials on hand to continue production while at the same time not having too much material on-site because there was limited storage space," he says. "This challenge was overcome by working closely with each of the manufacturers daily and constantly shifting delivery dates for each material as job-site conditions dictated."

The project's large size and aggressive schedule made it unique.

"The most rewarding part of the job was safely completing a roofing project of this size ahead of schedule and within cost," Busalacchi says.

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