CASE STUDY 2

A Prefabricated Roofing System Was Installed Relatively Quietly and Quickly

The EPDM roof was failing and nearing the end of its useful life on the Joseph Kushner Hebrew Academy in Livingston, New Jersey.

Multiple companies offered various solutions for reroofing the facility. The reroofing project had been left open to bid for five years and the school board had many options to consider before awarding the work for the 200,000-square-foot project.

Because the reroofing job was to be done over the existing EPDM system while school was in session, several factors had to be considered prior to choosing a bid.

Primarily concerned about the occupants of the building, the academy’s decision makers wanted a roofing option that would not produce noise or fumes and would be completed within budget and in a reasonable timeframe.

Although other options were considered, a prefabricated single-ply membrane was chosen for several reasons: 1) Its clean and safe application method met the requirements necessary for maintaining classes during installation; 2) The membrane manufacturer offered custom prefabrication; 3) The mechanical attachment; 4) Competitive pricing; and 5) The 15-year warranty.

The membrane’s high-reflectivity was also attractive to the board members, as it would save the school energy and money.

Scope of the Project

The job was enormous. It required flashing approximately 400 penetrations, including 126 HVAC units, on five different roof levels.

The flashings—made of membrane material that connects horizontal and vertical roof surfaces on rooftop protrusions such as curbs and stacks—are prefabricated in the manufacturer’s plant, and then delivered to the job site. Had the flashings not been prefabricated, workers would have had to manufacture them on top of the roof, during installation, which could increase the risk of worker error and thus increase the chance of roofing failure.

Because so much of the roof can be manufactured in a controlled factory environment prior to on-site installation, roofing contractors can typically complete jobs more quickly and efficiently and with less disruption than contractors using other systems.

The reroofing job required penetrations for about 400 penetrations, including 126 HVAC units, all on five different roof levels.

The school board was impressed by the roofing contractor’s ability to finish the job in just 60 days—less than the estimated timeframe—despite consistently poor weather conditions, which hindered the team’s progress.

Prefabrication also helped provide the assurance of a roof that would be leak-proof and virtually maintenance free, and under the protection of a vigorous warranty.

Planning and Preparation Before Installation

In preparation for the large project, the owner of the roofing company spent three days on top of the roof with the membrane manufacturer’s representative estimating the number of deck sheets that would be required. They also measured all of the roof’s penetrations.

As part of the academy’s roof replacement project, a uniquely designed pitched roof was installed on the front of the building, making the new roof impressive not only in terms of necessity and practicality, but also aesthetically.

Following the wishes of the school board, the installation team was successful in reroofing the Academy with no interruptions to classes. Staff and students held classes as usual inside the building during construction.