AD-A136 401 CONSTRUCTION OF ALUMINUM STANDING SEAM'ROOFING AT AN 1/1

ARMY FACILITY(U) CONSTRUCTION ENGINEERING RESEARCH LAB

(ARMY) CHAMPAIGN IL M ROSENFIELD NOV 83

ARCLASSIFIED "--mmmmmmm CERL-IR-M-336 F/G 13/13 NL

,EEEEEMEIImBEIm
*' ~ 1.2

MICROCOPY RESOLUTION TEST CHART

NATIONAL BUREAU OF STANOARDS-1963-A

I.I
Cff gll INTERIM REPORT M-336

Cawtrlion Engirneer November 1983

Research Laboratory

CONSTRUCTION OF ALUMINUM STANDING-SEAM

ROOFING AT AN ARMY FACILITY

I.

Mye by Rvefl

E

Approved for public release; distribution unlimited.

83 12 0 63
The contents of this report are not to be used for advertising, publication, o

promotional purposes. Citation of trade names does not constitute an

official indorsement or approval of the use of such commercial products.

The findings of this report are not to be construed as an official Department

of the Army position, unless so designated by other authorized documents.

DESTROY THIS REPORT WHEN ITIS NO I ONGER NEEDED

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e_
SECURITY CLASSIFICATION O 041 I A6E (When Date Eufmwdj

TITLE~~~S Bf Sil)TPEFIG REPORT NUERODCOERE

AUTI4OR(e) 10. CONTRACT OR GRANT NUMSERe)-

Myer J. Rosenfield Military Interdepartmental

Purchase Request No.

___________________________________________ 81-938-16

9. PERFORMING ORtGANIZATION NAME AND ADDRESS 10. P ROG RAM EL EMEN T. P ROJ EC T. T ASK

U.S. Army Construction Engr Research Laboratory AE OKUI UBR

P.O. Box 4005

Champaign,_IL__61820 ______________

11. CONTROLLING OFFICE MAME AND ADDRESS 12. REPORT DATE

November 1983

IS. NUMBER OF PAGES

25

14. MONITORING AGENCY WNK & AORESS(I Eff.,u~t ho Co'e,.lhae Offic) 1S. SECURITY CLASS. (at thle mport)

UNCLASSIFIED

I". D)ECLASSIFICATIONI DOWNGRAD)ING SCHEDULE

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141. SUPPLEMENTARY NOTES

Copies are obtainable from the National Technical Information Service

Springfield, VA 22161

- IS9. KEY WORDS (Centinwo en rower" aideit neoseary A"d Idmity by Woo*1 nm.)

roofs

aluminum

Defense Construction Supply Center, Columbus, OH

U A85UAC?(~ NI. -mow~

-- )This report documents the construction and instrusmentation of an aluminum standingwamn roofing system on a Defense LWgistics Agecy warehoius. The condition and

performance or the system arm being chocked and Icsted oft perludic inlervtal ft~it delemliIC

its behavior over annual cycles and to evaluate its capacity for long-term. i oublc-ftee

service.

This porion of the study observed the cutatmuction of the warehouse roof. including

t specifcations, matferals, and bulding procedures used. Future studies will investigate

S6CURITY CLaaSSFATSW OPTh"PA WSe5jJt

-df a Ro *,;e-
TSV CLM"PCATWN 0P TWO PASK(MtN b.aM

theffects of corrosion on the aluminum panels and continue evaluations of tempetatures

/and movement related to the system. The data will then be used to evaluate the roofing

system's behavior over two annual cycles.

This type of system shows promise of being a good, long-lauting reroofing system for

replacing deteriorated BUR, which is commonly used at Army installations. The contractor who installed the roof used good building practices, and these procedures can

serve as a model for future installations of this type of roofing.

LICIIFN

SICUMITY ~ ~ 14SPGM ~ ~ ~ O kCLAIIAINO ~ ~ ~ -
FOREWORD

This investigation was performed for the Defense Logistics Agency (DIM) by the

Engineering and Materials Division (EM), U.S. Army Construction Engineering Research

Laboratory (CERL). The work was performed under Military Interdepartmental Purchase

Request No. 81-938-16 dated 17 August 81. Mr. Marvin U. DuBois was tire DLA prto cl

monitor.

Appreciation is expressed to Mr. Gary Cattel of CTL Engineering, Inc.. for mnitoring

the construction of the roof for Warehouse 8, and to Mr. Herbert Neff of the Ohio River

Division, Corps of Engineers, and Mr. William Smith of the Facilities Engineer Office of

the Defense Construction Supply Center, Columbus, OH, for their assistance. Mr. James

Gambill and Mr. Willam Gordon of CERL made valuable contributions by designing and

installing the instrumentation systems.

Dr. R. Quattrone is Chief of CERL-EM. COL Paul J. Theuer is Commander and

Director of CERL, and Dr. L. R. Shaffer is Technical Director.

Accessi on For

NqTIS GP'4&I

DTIC TAB

Unann oun c-,

justificat-i~"--

Distribiitj on/

Availabilit*y Codes

Avail and/or

LDist Special

D4i

(C00Y)

I' _ _ _ _ _ _ _ _ _

wDI
CONTENTS

pop.

DO FORM 1473 1

FOREWORD 3

LIST OF FIGURES 5

1 INTRODUCTION ........................................... 7

Baskwond

Oblmiv

Ap~ of Ovrall Study

2 CONSTRUCTION .......................................... 7

3 TEST PROGRAM ........................................... 9

4 DISCUSSION OF OBSERVATIONS .............................. 9

5 SUMMARY .............................................. 10

DISTRIBUTION

4
FIGURES

Number Pap

I Warehouse No. 8. DCSC 11

2 Roof Model 11

3 Vacuum Removal of Loose Aggregate 12

4 Installation of Wood Sleepers 12

5 Detail of Roofing Panel 13

6 Application of Sealant 13

7 Foam Rubber Rib Closure 14

8 Rib Closure in Place Prior to Forming Seam 14

9 Placing Aluminpm Panel 15

10 Manual Crimper for Seam Ends 15

I1 Electric Seam Lock Tool 16

12 Ridge Cap and End Closures 16

13 Panel Attachment Clips 17

14 Counterflashing at Firewall 17

15 Flashing Details at Firewall 18

16 Counterflashing Step Intersection Details 18

17 Detail of Ventilator Flashing 19

18 Detail of Ridge Cap at Ventilator Flashing 20

19 Intersection of Ridge Cap and Ventilator Flashing 21

20 Peak of Ridge Cap Close to Top of Counterflashlng 21

21 Peak of Ridge Cap Above Top of Counterflashing 22

22 NBS Test Rack of Samples for Corrosion Tests 22

23 Cross Section of Warehouse 5 Showing Thennocouple Locations 23

S

I
FIGURES (ont'd)

Number POP

24 Arrangement of Elongation and Deflection Measurement Points 24

25 Typical Thermocouple on Aluminum Panel 25

26 Typical Elongation and Deflection Measurement Point 25

6
CONSTRUCTION OF ALUMINUM a. Observe condition and performance of the

STANDING-SEAM ROOFING AT AN roofing system at periodic intervals, and conduct

ARMY FACILITY required testing. This work would include checking

each component, such as panel, flashing, ridge cap,

etc., for corrosion, deformation, and movement.

1 INTRODUCTION b. Install gage points at appropriate locations to

measure deformation and movement of the roof panel.

Saclkpound c. Check flashings carefully to make sure they

Most Army facilities use conventional roofing perform as intended.

systems, such as built-up roofing (BUR), that are

sometimes expensive and complicated to construct. d. Measure temperatures of the metal roofing and

Such systems are often comparatively short-lived, the existing BUR with thermocouples.

resulting in high life-cycle roofing costs which are

difficult for already over-burdened Army operation e. Analyze panel samples at 6-month intervals to

and maintenance budgets to absorb. Therefore, the determine the extent and type of corrosion, using

Office of the Chief of Engineers asked the U.S. Army appropriate metallographic techniques such as microConstruction Engineering Research Laboratory (CERL) photography, scanning electron microscope, etc. This

to identify alternative, easy-to-install roofing systems task is being performed by the National Bureau of

that can improve the performance of Army roofing Standards (NBS).

and reduce its life-cycle costs.

f. Analyze and evaluate the results of these obserThe Defense Logistics Agency (DLA) was preparing vations and measurements.

to install aluminum standing-seam roofing on three

warehouses at the Defense Construction Supply Center The results of the analysis and evaluation will be

(DCSC) at Columbus, OH. This roofing was to replace documented in a final report at the end of the study.

BUR which had been installed only 6 yeaus previously.

Being aware of CERL's roofing investigation program,

DLA contacted CERL and the National Bureau of

Standards (NBS) and requested that they monitor

the construction and subsequent behavior of this 2 CONSTRUCTION

roofing.

Obiet*

The overall objective of this project is to determine At a meeting in July 1981, copies of the plans and

the behavior of aluminum standing-seam roofing over specifications were given to CERL and NBS for review.

two annual cycles and evaluate the capacity for long. In October 1981, a preconstruction conference was

term, trouble-free performance. This report documents held at DCSC in which comments from both agencies

the construction and instrumentation of the roof and all other details were discussed.

system for one of the three DLA warehouses on which

it was installed. Under the contract, three warehouses were to be

re-roofed: Nos. 8, 4, and 5, respectively (Figure 1).

Ap~ of OvwillStudy Each warehouse is 160 ft (48.8 m) wide by 1541 ft

The following tasks were established to accomplish (470 m) long, and divided by firewalls into I I apthe work: proximately equal sections, each about 138 ft (42 m)

long. Roofs are constructed with a slope of approxi1. Observe and monitor the construction of the mately 5/8 in. per foot (50 mm per meter). Roofing

roofing on the warehouses (documented In this report). panels are 1 ft (300 mm) wide. With panels continuous

from the central ridge to the eaves, each panel is 80 ft

2. Perform the following specific measurements and (24 m) long. Thus, there are about 3036 individual

observations on the roofing every 6 months for 2 yeaws: panels on each warehouse.

7
Because of the varied types of junctions and inter- placed at the two sleepers straddling the center of the

sections which occur in the roofs, the contract specified panels, permitting expansion at both ends.

that the contractor submit shop drawinp for approval.

In addition, the contractor submitted a model showing Figure 13 also shows the clip used along the firethese various conditions full-size (Figure 2). This model walls to hold the edge of the first panel under the base

was placed out-of-doors in an open location, so that it flashing. A stepped aluminum counterflashing was

was readily available for reference. installed (Figure 14) into reglets cut into the firewal

parapet. Because of the high winds that can be exConstruction on Warehouse 8 began on 12 April pected in the Columbus, OH, area, a stainless steel

1982, and was monitored by CERL. The first opera- strap was installed to provide uplift resistance to the

tion was removing, by vacuum, ail loose aggrepte from counterflashing. Figure 15 shows flashing details.

the existing BUR (Figure 3). Sleepers of 4 x 4 in. Figure 16 shows the intersection of counterfiashings

(100 x 100 mm) treated lumber were installed into at the step, including the uplift resistance strap before

grooves cut into the BUR membrane and insulation on it was bent up. The upper sheet was locked to the

5 ft, 8-in. (l.7541m) centers (Figure 4). Visible in the lower one by cutting a slit and locking the two pieces

grooves shown in Figure 4 are shims which were used together as shown.

to ensure that the tops of the sleepers were elevated

above the BUR surface to provide an air space between All this careful attention to detail, fabrication, and

the BUR and the aluminum panels. The sleepers were installation yields a roofing system which should proscrewed to the deck, which is a 2-In. (51 mm) tongue- vide many years of satisfactory service. The only

and-groove wood plank. deficiencies noted were related to design and installation of the ridge cap. On Warehouse 8, these occurred

The 80-ft (24-m) panel length is the longest standard where the ridge cap intersected the flashings at the

length furnished by the manufacturer from the factory. large central vents, and also occurs on all warehouses

Each panel is 1 ft (305 m) wide, with a 2 1/2-In. where the rdge caps ended at the flrewall parapets.

(64-mm) roll-formed shape on each side. Figure 5

shows a cross section of the panel. Panels used at The ventilator flashing intersection was detailed on

DCSC were .032 in. (.81 mm) thick. The sealant used the drawing shown in Figure 17. This shows a 5-in.

was a 3/16.in..4.75-mm-) diameter butyl strip on a (127-mm) vertical wall of the flashing, with the ridge

release paper. When placed as shown in Figure 6, it cap low enough for the connection to be completely

seals the standing seam and prevents entry of wind- within this dimension. As shown in Figure 12, the

driven or mow-melt water into the system. vertical height of the ridge cap should be at least five

times the expected roof movement. For 40 ft (12 m)

The eave end of the seam was sealed with a foam of aluminum over a temperature range of -20°F

rubber plug (Figure 7), applied before the seam was (-29C) to 120-F (49°C)-a difference of 140F

formed (Figure 8). This prevents entry of wind and (78C*)-the expected change in length is about 7/8 in.

water into the end of the sean. (22 mm). Following the recommendation of Figure 12,

the vertical height was set at 6 in. (152 mm). To

After the panels were st in place (Figure 9), the fabricate the intersection as shown in Figure 18, the

ends of the seam were crimped with a hand tool height of the vent flashing would have to be increased

(Figure 10), and the remainder of the seam locked to more than the ridge ap. Instead, it was made equal

with a traveling electric tool (Figure i1). The ridge to the ridge cap wall, and was actually fabricated to the

ends of the panels were formed into a pan end, sealed 6-in. (152.mm) dimension. This made the Intersection

with a closure that fills the panel from seam to seam, impossible to fabricate as detailed; the reult is shown

and then covered with a ridge cap (Figure 12). in Figure 19. A large mount of sealant was needed to waterproof these nterections.

Panels are retained in place by clips screwed to the

sleepers. Each clip has bulbs at the top which flt into The ends of the ridge caps at the parapets showed a

the won and prevent the roof panels from lifting off similar deficiency. In one case, the peak of the ridge

while permitting expansion and contraction. There are cap was very close to the top of the counteffiasbdng

two typas of clips: one Is for expansion, and one (Figure 20). In another, the peak of the ridge cap was

evw as an anchor (Figure 13). A button punch locks actually above the counterfadshng (FIgure 21). The

the p- ms to the anchor clips. These clip wrn picture shows the reglet into which the counterflsting

8

. o _
will be inserted, which has been primed with a black as shown in Figure 25. Figure 26 shows a typical

primer. Again, a great deal of sealant is used. elongation and deflection measurement point.

Neither of these details was addressed in the roof This instrumentation was installed in July 1982,

model. Figure 2 shows that the ridge cap was not and initial readings were taken. Subsequent readings

included when the model was prepared. If it had been, are being taken at 6-month intervals for 2 years, with

these deficiencies would probably have become evident the final ones in July 1984. These data will allow

before the roofing components were fabricated, evaluation of the roofing system's behavior over two

annual cycles.

Since these two ridge cap details depend greatly on

the sealant to keep them watertight, they will have

to be monitored very carefully to be sure that any 4 DISCUSSION OF OBSERVATIONS

deterioration of the sealant is repaired quickly and

thoroughly.

On the basis of observations made during monitoring of the construction, several features were noted

3 TEST PROGRAM that require careful monitoring over time:

1. Foam Seals. Foam rubber has a tendency to

shrink and harden. This could cause leakage problems

One of the tests to be conducted on the roofing at the ridge closures and at the rib closure plugs. The

system is determining the effects of atmospheric rib closure plugs could be particularly troublesome,

corrosion on the aluminum panels; this study is being since they are not adhered to the rib, and could thereperformed by NBS. A test rack containing 30 samples fore fall out if shrinkage occurs. A driving rain could

of the roofing material has been installed on one of the then penetrate under the panels, enter the cuts in the

parapets of Warehouse 4 (Figure 22). These samples BUR made to install the sleepers, and leak into the

will be removed at 6-month intervals and analyzed to building.

measure the rate and type of corrosion and to determine its effect on the material. 2. Ice Dams. Ice dams result when water from

melting snow freezes on a cold overhang. Thus, water

CERL has installed devices to measure temperatures can build up over the leve! of the rib and seep through

and movement related to the system. Instrumentation the seam if it is not sealed properly. If the butyl sealing

was installed in the fifth bay from the north end of strip used to seal the seams dries up, hardens, and

Warehouse 5, 37 ft (12 m) from the north end of the cracks, the seam will be susceptible to leakage.

bay. Six stacks of thermocouples were installed, three

each on the east and west sides of the warehouse 3. Wind Uplift. The system was installed with

(Figure 23). One thermocouple was attached to the special features to guard against wind uplift damage

lower surface of the roof deck to measure interior (e.g. heavy-duty clips, counterfiashing straps), so this

temperatures, one to the top of the existing BUR, and should not be a problem. However, flashings and

one to the top of the aluminum roof panels. Also, one edgings should be checked periodically to ensure that

thermocouple was mounted on an interior column near these provisions were adequate.

the switching box for all the thermocouples, and

another thermocouple was mounted in an external 4. Corrosion. The system was designed and installed

shielded location to determine ambient temperatures. to minimize corrosion problems from contact of

In all, 20 thermocouples were installed. dissimilar metals. To eliminate any sources of galvanic

corrosion, all fasteners and accessories are made of

Elongation and deflection measurement points were either aluminum or stainless steel. The corrosive

established in the panel adjacent to the one with the potential of the Columbus, OH, atmosphere is being

thermocouples, but were placed I ft (305 mm) closer monitored by NBS.

to the nearest firewall parapet. Figure 24 shows arrangements of these points. 5. Thermal Movement. The theoretical thermal

capabilities of the roofing system are excellent, since

Thermocouples were epoxied to the aluminum the panels are free to expand and contract longitusurface and covered with aluminized silicone sealant, dinaly, and their cross section shape permits transverse

9
movement without inducing excessive stresses. Thermal

response is being monitored for 2 years following 5 SUMMARY

installation of the instruinentation.

Special care is necessary during roofing design to This report has documented the construction and

ensure dimensional compatibility of all components. instrumentation of an aluminum standing-seam roof

Metallic roofing cannot be formed in the same manner system on a DLA warehouse. This type of system

as single-ply membranes or sprayed polyurethane foam. shows promise of being a good, long-lasting reroofing

Sometimes tile only way design errors can be corrected system for replacing deteriorated BUR. which is

in the field is with excessive use of elastoneric sealant, commonly used at Army installations. The contract,

which is not supposed to be installed in thick applica- who installed the DLA warehouse roof used good

tions. As this sealant ages, it cracks or splits, this will building practices (see Chapter 2), and thcse procecause leaks to develop and allow water to enter the dures can serve as a model for future installations of

system. this type of roofing.

10
Figure 1. Warehouse No. 8. DCSC.

Figure 2. Roof model.
Figure 3. Vacuum removal of loose aggegate.

Figure 4. Installation of wood sleepers.

12
Bulb rib with

Pencil anti- siphon groove

Ve'2standing rib

Sealant

Stnding sam is roll-fortmed by zipper tool to locked poiti s~

Before After

zip closure zip closure

Figure S. Detail of roofing panel.

Figure 6. Application of sealant.

13
Rib Closur

Cut from I" foam rubber, this closure compres- (1 s"nto Meal bulb rib and between legs of ad)oin_ I

Ing rib*.

Figure 7. Foam rubber rib closure.

Filmr S. Rib closure in place prior to forming seam.

14

I -M
Rpmus9. Placing aun pawl.

Flpse 10. Manual crimper for seam ends.

is
Fipre 11. Electric seam lock tool.

r ma ow

ali. Fi"r RIcpaden lsrs

zww Too

fItm ~ow
a -k

CLIP

DESCIW- PANEL CLE*Rt

TKNAND BASIC NEV

NUMBER CON3URATDN NONAL DUENSIONS IXW

-- 4 1 tO- W"A

UP'

Cu,, a0

Gableim . ~ sa - 3/0"

2002 -

_________" e-_ N. it5 A . m 

Figue 13. Panel attachment clips.

Rlpmr 14. Counterfiashing at firewall.

17
S ~ WiTEN FLASHING

* IUPT FsAMGUMM Pft.

WAS

Figme IS. Flahing details at firewal

Flmw 16. Couteffmdnl stop iawsction detail.
Fkm 17. Douag of ventilator flauhk4.

19
ALUMINUM FLASHING

STAINLESS STL. SCREW W/

NEOPRENE WISHER

SEALANT NO 4

ALUMINUM RIDGE CAP

SECTION 'A

ALUMINUM FLASHING

02

.4 'no
Fima 19. Intersection of ridge cap and ventilator flashing.

Fig.. 20. Peak of ridge cap close to top of counterflahing.

21

'II
1.21. fnk of dtg, cap abov, top ofcoouuulmbdmg.

22
V F 2 V) t t 

S cDO

0

~60

q~Ln 0 0

anon

-0-

I0 _ 

23.
30 -

29

28

TG10X27

T6IX2 6

25

24n

id 23

20

19

TIO-12 XIB8

17j

16 5

15

14T

T7-9 X1

12

10 1

8dT4-6 X 9

7

6

T1-3 X

4

4 ~140'I '

Figure 24. Arrangement of elongation and deflection measurement points.

24
Figure 25. Typical thermocouple on aluminum panel.

Figure 26. Typical elongation and deflection measurement point.

25
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Ii
boenfield. Myer J.

Construction of aluminum tanding sam roofing at an Army facility. -

Chemaigm. IL : Costcruction Egineering Research Laboratory ; available

from NTIS, 1903.

25 P. (Eate.tu report I Comtructioa Zoineering Research Laboratory

M-336)

1. Roofing, alumia-m. 2. Defense Construction Supply Center, Colubu. Ohio. 1. Title. 11. Series Interim report (Conatructlon

MIliaemerln Research Laboratory) N-336.

1'1