Projects Portfolio

State Farm Insurance
Charlottesville VA

Project Type: Green roof, roof replacement
Material/System: Extensive green roof, Siplast 20 year modified bitumen, Kynar finished metal, Siplast fabricated
Size: 8.5 acres

State Farm was looking to strengthen their position as a leader in green building. The Charlottesville, VA location asked Tecta America to install a 500 sq. ft. green roof, including 5 inches of soil media and drought-resistant sedum plants. These plants help eliminate storm water runoff and lower utility costs.

In spite of some early difficulties, we completed the replacement of 8.5 acres of roof and 5,000 linear feet of fascia ahead of schedule. Today, State Farm’s employees gain a measure of satisfaction working for a company that is committed to environmentally friendly construction.

500 Capital Mall
Sacramento CA

Project Type: New construction
Material/System: Single-Ply

500 Capital Mall is the address of Sacramento’s newest high-rise showpiece, The Bank of The West Tower. Reaching 400’ above the valley floor this modern structure hosts eight different roof levels, all consisting of tapered insulation, cover board and an adhered single-ply roofing system. Additionally, we fabricated and installed an elaborate contoured aluminum cornice and parapet framing system. Two of the roof decks are accessible to the public and incorporate high-density concrete plaza pavers and adjustable pedestals as the walking surface.

Natomas East
CA

The Natomas East Office Building with views of Sacramento’s scenic American River Parkway was completed in 2009. This multi-level roof structure is protected by a 20 year TPO Single Ply Roof installed by Tecta America.

Pearson Ventures Office Building
North Billerica MA

Capacity: 143kW

This is the Tecta America New England Headquarters Building. It was a good economical decision to install solar photovoltaics across this 30,000 sq. ft. roof. Additionally, since the roof is accessible, it serves as a great show piece for customers to view directly. Furthermore, the 1,428 sq. ft. TectaGreen Modular Vegetative Roof draws appeal.

The most challenging aspect of this project was handling all of the required paperwork for a myriad of government incentive programs, permitting, and utility connections. Yet, we pride ourselves on our ability to handle this complicated process to save the owner countless hours of frustration and to provide them with a simple, turn-key solution. In the end, the project was completed successfully with no disruption to the building occupants during the construction.

Vantage Point Building
Sanford FL

Material/System: Thin Film Photovoltaic Roof System
Size: 40,000 sq. ft.
Capacity: 25.4kW

This building was constructed in 2007 as the new office location for Tecta America Central Florida. It accommodates 180 field and 30 administrative staff, truck fleet, equipment, and resources. At just over 40,000 sq. ft., this roof structure was engineered to hold a vegetative roof system, solar photovoltaics, solar thermal, and daylighting technologies.

Bank of the West
CA

Material/System: High Steel Safety Railing Installation
Size: Approximately 500 lineal feet of min. 42" high steel safety railing on various roof levels of a 30-story high rise

Date Installation Began: July 10, 2010
Date Installation Completed: July 30, 2010

Since we had performed the original roof installation we knew all the details of the various roof assemblies, we were already responsible for the two year roof warrant, and we had a very strong relationship with the architect

We were working nearly 400' off the ground while working at the edge of the roof with only a 24" parapet wall. The concrete drilling had to be performed during off hours as to not disturb the building tenants. Getting all the materials and tools up to the various roof levels using freight elevators was a difficult process.

Our people were 100% tied off the entire time on the roof. All of the tools and materials used near the edge of the roof were attached to lanyards to prevent accidentally dropping them down to the streets below.

We installed 1.5" steel piping, base plates steel couplings, specialized fasteners, custom flashings, laser levels.

The building was a recently built, beautiful structure in downtown Sacramento located on the Capitol Mall. Every roof level was visible from the offices on that floor. Everything had to be done flawlessly, as everything we installed was going to be seen for many years to come.

BP Amoco
IL

Project Type: White Reflective Roof

Date Installation Began: June 2010
Date Installation Completed: October 2010

We have been doing work for BP Amoco over the past two years and as a result they awarded us the project due to our proven quality, safety record, and value.

It was a challenge to work at maximum productivity while trying to keep the noise level to a minimum in order to not disturb the employees in the building. Nonetheless, we finished this project according to the estimated hours scheduled.

The tear-off was completed relatively quickly with the crew beginning at 6am and completing the tear-off that same morning at 9:30am. All of the tear-off materials were lowered by crane into dumpsters. We had built railing around the entire roof perimeter to ensure our safety while working.

ProLogis/FedEx
Phoenix AZ

This 126,300 square foot project was a reroof project using a Johns-Manville 60 mil TPO specification. The existing roof was a built-up capsheet roof which had reached the end of its life cycle. Making this project somewhat complicated was the fact that most of the existing roof was original and did not require tear off, while a 40,0000 square foot section had two layers of roofing and did require tear off and a layer of polyiso insulation to bring it up to the same level with the remaining roof. Johns-Manville Invinsaboard was installed over the existing roof/polyiso prior to installing the mechanically attached 60 mil JM TPO roof.

In addition to installing the new roof, we also upgraded many of the electrical supply lines to the A/C units and evaporative coolers. Many of these supply lines were underneath the evaporative coolers and were relocated to a more accessible location. Integrity Heating and A/C worked as our subcontractor and helped in completing this electrical work. We also worked with Integrity to install new evaporative cooler jacks and new A/C duct jacks, bringing the mechanical equipment on this roof up to nearly-new condition.

New wall counterflash metal, metal vents, and a sheet metal-covered firewall were some of the other improvements added when installing this roof. New sheet metal gutters were also fabricated and installed. Parapet walls, curbed skylights, and equipment curbs were flashed with JM 60 mil TPO. The new roof was an improvement not only from a technical standpoint, but it was also very pleasing to the eye – a big improvement over the old built-up roof!

This roofing project was challenging in many ways. ProLogis, one of our most valued customers, is very protective of their tenants – especially one as high profile as FedEx. A lot of coordination and attention to the concerns of the tenant went into this job. It is a testament to our superintendent, foreman and production crew that FedEx experienced no problems during this reroofing project. The work started in late February, 2010 and was finished within 60 days. The customer was very happy with the finished project, as they have had us reroof several more of their buildings using Johns/Manville 60 mil TPO.

Catholic University
DC

Project Type: Solar
Material/System: Ballasted Sunlink Framing and Suntech-Power PV Panels
Capacity: 293kW

Date Installation Began: October 27, 2009
Date Installation Completed: December 4, 2009

Catholic University had four buildings across this campus. Tecta America Magco worked with various trades to get the project done on time within the confines of a challenging schedule

Tecta America Magco had some manpower issues and prior commitments. This problem was solved by tapping into the labor resources of both Tecta America Potteiger and Tecta America RoofersInc. This not only allowed for sufficient manpower, it also allowed Tecta America Potteiger and Tecta America Roofers Inc. to gain valuable solar installation experience under the supervision of Tecta America Magco personnel with previous PV installation experience.

Crawford Woods Elementary
OH

Project Type: New Construction
Material/System: Modified bitumen roof system applied in hot asphalt and a metal roof with 22-ga prefinished steel, standing seam roof panels
Size: 67,500 sq. ft.

Date Installation Began: September 2009
Date Installation Completed: October 2010

In addition to challenging logistics, the standing seam roofing install was a difficult task to conquer. The roof structure was open framing with eave heights of +/- 40'. The install was slow given each panel had to be raised from the ground with a lift and set into place by several men. This was after one layer of vinyl faced batt insulation was draped tightly over the framing and held in place by two-sided tape. The Tecta America Carolina's office offered manpower and expertise with the open framing install, which dramatically and successfully contributed to the success of this project.

Safety was a large concern of the sheet metal roofing. Safety meetings were performed and documented daily. The need for having men at the eave was eliminated by using a man lift to perform the work at the eave. Each installer was tied off 100% of the time without exception. Once the panels were installed the men tied off to standing seam roof brackets. The install was slow, but safety was our #1 priority.

Denver Central Platte Campus
CO

Project Type: New Construction
Material/System: 62,273 sq. ft. EPDM Roofing & 24,000 sq. ft. Sheet Metal Panels & Wall Panels

Date Installation Began: September 28, 2009
Date Installation Completed: November 15, 2010

Tecta America Colorado began working with Pinkard Construction and RNL Design (Architect) during the budget and design phase of the project. We helped determine construction details vs. budget issues and ultimately products to be specified.

We installed an EPDM Roof System, coordinating Install on 3 different buildings at one time with multiple crews.

There were two different EPDM roof types and sloped roof applications (1/4"" slope vs. 3/12). We also installed Isolation of vapor barrier on different roof areas and a Metal Roof System and with wall panels. The long length of the panels required simultaneous use of multiple lifts.

To adhere to safety standards we used 100% personal fall protection, safety carts, guardian safety lines (cable lines), guardrails, and underwent safety training for lift equipment.

East Harris County
TX

Project Type: New Construction
Capacity: 145kW over 2 schools

Date Installation Began: September 19, 2010
Date Installation Completed: December 18, 2010

Each building was unique in design for a reason; so the high school students could collect and compare data from each panel array over various roof surfaces in their science classes.

By far, the trickiest section of the project was located on the Building "D" awning. The crews had to work on a cantilevered ledge that was only 2'3" wide, so we were tied off 100% of the time to our fall protection cart. We were also forced to bring in a man lift to reach a far edge of the awning installation. This extra cost not only sped up production, but also gave the crew a feeling of safety and well-being standing and working in such tight quarters.

We established ourselves as a leader in the Houston solar community with the hopes that our reputation will continue to thrive.

U.S. National Whitewater Center
Charlotte NC

Project Type: Solar Installation
Material/System: Solar thin film
Capacity: 5 kW

The USNWC is the first facility in the Charlotte region to generate a portion of its operating power with a thin film panel roof system. The thin film uses low-light technology to produce more electricity per watt than other systems currently on the market. The 5kW system will generate a cost savings for the Whitewater Center and is expected to become an important educational tool for the community. In the conference center lobby, an easy-to-use touch screen allows viewers to access real-time information on statistics like kWh generated, and environmental offsets including the number of trees saved and pounds of carbon offset.

Humboldt State University
Arcata CA

Built on the beautiful campus of Humboldt State University, the new Physical Education Building gave us the unique challenge of matching the environmental surroundings. The combination of the colonial red curved standing seam metal roofing and the mystic grey fluted metal siding accomplished that objective. With just over 83,000 square feet of metal roofing, single-ply roofing and metal siding this project ranks up at the top in terms of scope and difficulty.

Children's Museum
Indianapolis IN

Project Type: Roof Replacement
Material/System: Copper panels, scaffolding
Size: 69,000 sq. ft.

This project presented a unique challenge: it needed a new roof and also required the installation of a copper flat lock panel roof installed over the planetarium dome. Our client had numerous leaks over time and had hail damage from a recent storm, and chose Tecta America because of our expertise in sheet metal craftsmanship as well as having the resources required to install copper. The project necessitated cantilevered scaffolding, requiring expertise and skilled workmanship to complete since it was a step-by-step process. To help save on heating costs, we proposed that the customer use additional thermal value on the four flat roof replacements. The museum was completely satisfied with the result—a leak-free roof and lower heating costs.

Waxhaw Elementary School
NC

Size: 99,000

This project was a 99,000 square foot existing shingle roof that was replaced with Fabral Amp Lock panels.

Safety was a number one priority on this job, as school was in session while the reroof took place. Not only were our employees vigilant about safety on the roof, the campus was open to students and faculty, and on the ground safety was just as important.

Due to various school functions taking place, our crews had to ensure the job site was cleaned daily and work was scheduled accordingly. Even with these special considerations, the project was completed safely and on schedule.

Camino Nuevo High School
CA

Size: 100,000 sq. ft.

This project included the installation of 100,000 square feet of solid and perforated metal wall panels. We were referred to the general contractor by the architect because of our past success with this specific type of work. The most challenging aspect of this project was the architect’s design amendments once construction was underway. This was such a unique project that once complete, received attention with a 7 page article featured in the July 2007 edition of Architectural Record.

Barron Collier High School
Port Charlotte FL

Size: 2,614 sq. ft.

This was a 2,614 square foot re-roof project. Wright Construction called upon us to complete the project as we were the preferred vendor. We performed all of the work at night to avoid disturbing the students and faculty. As a result, we’ve been awarded additional projects from the School Board.

Holocaust Education Resource Center at the University of Maine Augusta
Augusta ME

Project Type: New Construction
Material/System: EPDM fully adhered, metal siding copper
Size: 10,500 sq. ft.

This is a permanent exhibit depicting the history of the Holocaust, so the client needed a company that could handle building design and the delicate job of fabricating and installing copper panels. The Center needed to have a modern architectural look, so we installed an EPDM fully adhered and metal siding/copper roof. Our expert metal installers met the client’s requirements, completing the project within the scope and time frame necessary. Today, the Center acts not only as a memorial to the victims of the Holocaust, but also a showcase of modern architecture.

Palmer Ridge High School
Monument CO

Project Type: Green Roof
Material/System: Intensive green roof
Size: 129,148 sq. ft.

The school district wanted to incorporate green in new concept design. TectaGreen, the nation’s leading green roof installer, was selected to work on the multi-phase project. This LEED project included an intensive green roof with two waterproof membranes. Upon completion, the project received multiple awards. Today the district is educating both the public and students about green roofs, using this project as the model.

ASU Bateman Hall
AZ

During the course of bidding for maintenance and repairs for the summer construction programs at Arizona State University, we were asked to submit a reroofing proposal as well as the standard maintenance and recoating specification work by the university maintenance department.

Building "F" has numerous exhaust fans and curbs serving the six story building labs and classrooms under the main roof area. This is a critical area as the labs below cannot be shut down and noise and odor has to be kept to a minimum due to the many experiments being conducted in the labs. Over forty exhaust fans, numerous HVAC units and hundreds of feet of vents criss-cross the 7300 sq/ft of roof surface. The existing roof was ten to fifteen years old and showed signs of leaking and deterioration under the units and curbs. All work had to be done at night to control the smell and odors so a smooth surface “peel and stick” SBS coated capsheet BUR assembly was specified by Tecta America AZ. to meet these project requirements.

Tecta Arizona’s price to remove and reroof the 7300 sq/ft came in under budget and was accepted by the university to start on approximately June 1, 2009. We brought the project in under schedule and actually finished one to two weeks ahead of the proposed time for reroofing in this area. As a team, Tecta America was able to meet the challenge and keep the university, general contractor and architect happy with the work being done and on the approved bid list for future roofing/waterproofing projects with the university.

United States Coast Guard Hangar at Otis Air Force Base
Bourne MA

Project Type: Roof Replacement
Material/System: White TPO
Size: 30,000 sq. ft.

The existing Built-Up Roof needed replacing and the external steel structure needed to be prepped and painted. We installed a high-performance, Energy Star Rated TPO "Cool" Roof with two layers of R=30 Polyisocyanurate insulation.

This project was unique as the building was adjacent to the Coast Guard Air Strip so precautions needed to be taken using the crane and driving vehicles around the base. As the hangar was fully-occupied with jets and helicopters, extreme caution had to be taken with the roof removal process. We were also responsible for painting the outside steel structure.

The project was a great success as the hangar remained fully-operational during the construction process and the project was completed on time and on budget.

With the installation of the “cool” roof, we were able to help the owner save dramatically on energy costs due to both the white reflective surface and increase in Insulation R-value.

The project went through our typical pre-job safety planning, on-site specific analysis and meetings with the owner's representatives. This project's unique safety requirements included construction vehicles driving on the air base and our crane and boom lift extending into the air space.

Federal Reserve Bank
Charlotte NC

Project Type: Green roof, roof replacement
Material/System: Extensive green roof
Size: 83,355 sq. ft.

Completed in 2008, this project had many elements which contributed to the project’s complexity: a high profile, high security of a Federal Reserve Bank; heavy traffic and complicated logistics of a busy downtown setting; a waterproof membrane being installed on multiple levels of different elevations and size; almost 1,000 tons of expanded slate growing medium; and approximately 50,000 sedum plugs.

By coordinating closely with the Federal Reserve Bank, the engineering firm and City officials, we were able to navigate all the logistical issues. We installed an electric field vector mapping system to negate the possibility of costly roof inspections searching for leaks. By using RK Hydrovac’s blower truck to distribute the growing medium, we saved a considerable amount of labor—and reduced our client’s costs significantly.

Ft. Carson Military Base
Ft. Carson CO

Project Type: Roof Replacement
Size: 179,100 sq. ft.

This is a LEED, design-build project that we landed due to our close relationship with the architect and general contractor. We worked on the project from inception through completion. This was a full design process as we started with the client’s budget then put a plan together before being awarded the roofing work 8 months later. Ultimately we provided them best value scope and price for # of buildings. This project was successful in that the client was satisfied and continues to contact us for work on more of their buildings.

USPS Morgan Building
New York NY

Project Type: Green Roof
Material/System: Semi-intensive green roof
Size: 109,000 sq. ft.

As part of the Postal Service’s greener facilities strategy, the organization established a goal to reduce energy use 30% by 2015. And in fall 2008, the USPS Morgan Processing and Distribution Center in Manhattan selected Tecta America to install a semi-intensive green roof on the 7th floor of the facility. Our crews completed the project in July 2009 within budget, making it the largest green roof in New York.

Additional facts about the USPS green roof:

• The roof will last 50 years—twice as long as the previous roof.
• It will reduce the amount of polluted storm water runoff into the NY municipal water system by as much as 75% in the summer and 40% in the winter.
• Projected to save the postal service $30,000 yearly on heating and cooling costs.
• Plants and vegetation are native to the region and comprise approximately 59% of the roof.
• Nearly 90% of the original roof was recycled and reused on the roof.

Tufts Healthcare
Watertown MA

Project Type: Roof Replacement
Material/System: White TPO fully adhered
Size: 28,000 sq. ft.

This historic structure was constructed entirely out of limestone in 1931 for Western General Electric. The building includes a 200’ tower that housed the original fire suppression water tanks. Tufts purchased the building and did a complete rehabilitation to properly house their Health and Life Center.

Tecta America was brought in when the existing roof system had severe ponding and leaking issues. Having performed hundreds of roof removals in owner-occupied buildings, we had the equipment and expertise to take care of the removal and installation without disruption to the business.

We used a crane to lower the existing roof into a dumpster, thereby avoiding dust and debris, and keeping the work environment safe for employees. We avoided internal fume issues by using a low VOC bonding adhesive to adhere the membrane to the installation. The new system was installed with no incidents, on time and on budget.

Church of St. Gregory the Great
Portsmouth RI

Project Type: Historic Restoration
Material/System: Custom fabricated copper
Size: 9,224 sq. ft.

Our client needed to restore an important community landmark. But this was no ordinary project; they needed a company capable of performing very intricate custom copper work in the dead of winter. It required the right kind of expertise and enough manpower to keep the project on a tight schedule. We were selected due to our experience with performing historic copper restoration work since 1988, and because we have one of the largest copper crews in New England. We worked on the oceanfront property during winter, installing new ice and water shield over plywood substrate, custom fabricated copper flashings, roofing, siding, gutter and downspouts to match existing. We completed the project on schedule—in time for the grand re-opening of Easter services.

Target Center
Minneapolis MN

Project Type: Green Roof
Material/System: Extensive green roof
Size: 2.5 acres

One of the projects we take most pride in is the Target Center in Minneapolis. Located in downtown Minneapolis and varies from 150ft. to 170ft. in height with 31 different roof areas. The City of Minneapolis—the owner of the Target Center—selected Tecta to construct, install and maintain an extensive green roof. Today, it holds the largest green roof in Minnesota and the fifth largest in the country.

The green roof features a 2.75” growing zone in the center of the main arena roof structure and a deeper 3.5” growing zone around the perimeter where the structural capacity is greater to maximize storm water retention and plant vigor. The roof uses the pre-grown mats as the base of the green roof system and is complemented by additional plantings to enhance plant diversity and ecological resilience. The roof features a mix of sedum and native plants and a drip irrigation system provides water to the plants during establishment (for the first 1-2 years).

More than 11 miles of sustainable, water-efficient irrigation lines were installed. In addition, we laid 14,000 cement pavers for firebreaks and roof protection.

While the project called for 50% of recycling materials, our team set a goal of recycling 100% of the old roof, resulting in an estimated 450 tons of existing rock and 590 tons of existing pavers, 140 tons of existing roofing membrane and more than 60 truckloads of existing roof insulation.

The green roof features a state-of-the-art waterproofing membrane that will withstand constant dampness, high alkalinity, exposure to plant roots, fungi and bacterial organisms as well as varying hydro static pressures. A leak detection system called Electro Field Vector Mapping (EFVM) is used to pinpoint leaks in the membrane.

Additional facts about the Target Center green roof:

• The green roof will handle up to 0.9in. of 20 rainfall w/o runoff, capturing an estimated 1 million gallons of storm water per year.
• It will mitigate urban heat island effect by reducing the roof temperature up to 80 degrees Fahrenheit.
• The waterproofing membrane expected to last 40 years.

Greyhound
Chicago IL

Project Type: Roof Replacement
Size: 17,743 sq. ft.

The Greyhound Lines station roof in Chicago was about 20 years old and had deteriorating detail conditions around the mechanical penetrations. It was due for replacement.

However, the cost of the project was greater than Greyhound’s budget. As a result, we suggested a system that was closer to their spending expectations while still meeting their requirements of a 20-year warranty.

Located downtown, in an urban environment next to an expressway, the rooftop could be viewed from the vehicles passing by. Given the severe Chicago winters—heavy with ice and snow—it was critical that the gutter details be installed exactly right.

Tecta America successfully completed the project on time and without incident.

McDonald's Lodge
Oak Brook IL

Project Type: Roof Replacement
Size: 4,878 sq. ft.

The client had a roof section that needed to be replaced. But because the restaurant resides in a lodge, the project needed to be completed without disturbing any of the guests. As a result, the client requested that our daily schedule be 8 a.m. - 4 p.m.

Upon roof analysis, we suggested a thicker membrane be installed to make the roof last longer. Since the owners wanted all roof areas to retain the same look, we had to move the rock ballast on the building and then put it all back into place—and do it all with limited crane access.

Despite these challenges, there were no complaints from guests about noise level, cleanliness or any other aspect of our work. And since completion of the project, Tecta America has been asked to do additional work at the McDonald's lodge.

Seadog Brewing Co.
Portland ME

Project Type: Solar installation, roof replacement
Material/System: Solar thin film panels with EPDM
Capacity: 5 kW

Our client’s goal was twofold: create an eating area that not only looks attractive to patrons, but is also environmentally responsible. The experts at TectaSolar worked closely with the client to design the system. We introduced the client to state-of-the-art solar panels that have an extremely thin profile, offering a uniquely aesthetic look. We created a structural steel awning using an EPDM roof and 80 flex light thin-filmed panels. The project was completed on time and the result is an energy efficient, attractive dining destination patrons.

Cinemagic
Westbrook ME

Project Type: New Construction
Material/System: TPO white mechanically attached with panels
Size: 79,000 sq. ft.

The client knew of Tecta America’s ability to handle unique metal fabrication and installation, and our track record of completing projects on time and within budget. We supplied and installed the complete exterior skin of this movie theatre, including five different colors of complex metal siding and a TPO white mechanically-attached roof system. We coordinated the ordering and fabrication of the metal panels, installing them horizontally and vertically. The theater opened on time, and serves as representation of the relationship between metal design architecture and professional installation.

Kennebunk Service/Travel Plazas
Kennebunk ME

Project Type: Roof Replacement
Material/System: Metal panels with PVC fully adhered
Size: 65,000 sq. ft.

These travel plazas, located on Interstate 95 in Kennebunk, Maine, needed roof replacements. The projects had to be completed on opposite sides of the highway simultaneously—while the buildings were in use.

The client knew of our ability to coordinate all aspects of equipment rental, materials and installation in a safe, timely manner. And with our experienced management team and expert metal installers, we completed the project on time, with minimal disruption to travels.

Today, these plazas provide travelers with a beautiful place to eat, refuel and recharge.

Staples Center
Los Angeles CA

Capacity: 512 kW

Tecta America was contracted by Solar Power, Inc. to provide the installation capabilities for this 512 KW rack and panel system. Due to the large number of roof penetrations for the sighting of this system, we were contracted to install the stanchions and then to attach them to the roof while patching the area around the stanchions. The installation was performed while maintaining the existing roof warranty for the building owner.

School of Creative & Performing Arts
Cincinnati OH


This project involved 19,200 square feet of Millennium Tiles 24-ga 16”x 9” stainless steel siding tiles. The installation of these tiles was complicated in that it involved two shades of tiles installed to form a diamond pattern on the building reaching heights of 80’. Additionally, a second siding system of 25,200 square feet of Una-Clad 22-ga 60”x16” zinc flat lock tiles were installed.

As a result of the architect’s design and a quality installation, the building is received national recognition. In spite of the size and complexity of this project, it came in under budget and contributed toward Tecta America Zero Company’s attainment of the Associated Builders and Contractors Gold S.T.E.P. Award and Platinum Level Awards for safety excellence.

Federal Aviation Administration Facility
Aurora IL

The Federal Aviation Administration (FAA) issued a request for proposals to have various work completed at their Aurora facility. We were hired to complete the 6,800 square foot roof due to our demonstrated ability to complete the project within detailed specifications and on-time. The most challenging part of this project was to ensure that the application of the roof coating be applied in a short timeframe and under ideal weather conditions. The application had to be done during a series of days where no precipitation occurred and had to be completed before the temperatures started dropping to the point where it would be too cold to apply the coating.

Ford Motor Company
Chicago IL

Since 2003, we have re-roofed over 200,000 square feet on Ford Motor Company’s local area plants. Therefore, when their large Chicago plant had sections on their complex due for replacement, we were awarded based on our proven performance to finish a good quality job. This 18,100 square foot roof section was for a building that had just been added on to the plant. We proposed a roof system that was compliant with the City of Chicago’s new energy code. A challenging part of this project was that the new addition was being roofed adjacent to the building where new automobiles were being painted through an assembly line. The work had to be completed without interruption to the painting process. It was imperative that the building next door stay dry at all times. The weather was also a challenge during the project as production took place as the temperature varied from a low of 10 degrees Fahrenheit to a high of 60 degrees Fahrenheit. The job was completed in 100% compliance of strict OSHA safety requirements.

Nestle, U.S.A.
Franklin Park IL

Project Type: Roof Replacement
Size: 40,000 sq. ft.

Nestle's Franklin Park facility had a number of aging roof sections that were due for replacement. The client chose Tecta America because of our track record of providing roofing services to the food manufacturing industry, as we know how important it is to minimize interruption of foodservice production lines. And with our dedicated service department, we were able to service existing roof sections that only needed maintenance.

The locker room section was re-roofed before leaks could permeate the membrane and make the insulation wet. We were then able to save the client the cost of replacing the insulation, as only an overlay of new membrane was needed rather than performing a complete tear-off. While removing the old sections, it was imperative that we kept the facility below dry, while also keeping the clean white appearance of the installation looking new.

As a result of our success, Tecta America has been awarded ongoing roof maintenance and additional roof replacement opportunities.

Honda
Greensburg IN

Size: 1,269,120

This project was a new assembly plant that had to be completed under a critical deadline. The general contractor was confident in our ability to meet the manpower requirements and complete the 1,269,120 square foot roof on deadline. One of the most challenging tasks was the coordination of multiple truckloads of materials with other trades and their material deliveries while installing the roof.

Duracell Plant
Lancaster SC

Size: 95,000

This was a 95,000 square foot complete roof replacement. The existing roof consisted of a built up roof over 2 inches of fiberglass insulation. Over the BUR was a sprayed urethane foam. The flashings were abated for the asbestos. The steel decking was cleaned and an epoxy paint was applied with a 6 mil poly sheet on top. A temporary roof was installed with dens deck and one ply torched modified bitumen membrane. The main roof consisted of two layers of insulation with tapered at several areas, dens deck and 2 ply torch applied modified bitumen membrane. New pipe supports were installed as needed and the existing larger supports required temporary shoring to replace the roofing under them. A new aluminum pipe railing system was installed around the perimeter anchored to the wood blocking below. As this plant runs 24 hours a day, seven days a week, a subcontractor, Tuff Wrap, was hired to install interior protection so the plant would not be interrupted of their daily work. The project was completed in approximately 8 months.

Energizer Plant
Ashboro NC

Energizer Batteries in Ashboro, NC. has a new state of the art daylighting system from Orion. We installed 110 Orion Lightpipes on Energizers warehouse facility. Along with the light pipes was an interior lighting control system that complimented the natural light coming into the building. The interior lighting was on an IntelLite control system that would shut off one bulb at a time until the entire building was illuminated by natural light. The system will save Energizer almost 50% over their existing lighting cost.

Thames River Bridge Rehab
Groton CT

Project Type: Roof Replacement
Material/System: Modified bitumen SBS cold applied
Size: 700 sq. ft.

Severe leaks had gotten into Amtrak’s main control room for the Thames River Bridge. This unique project involved a roof 100 feet in the air, surrounded by water, with access via barge and track only.

The solution was to remove the existing built-up roof system and replace it with a cold-applied SBS modified bitumen, along with a layer each of one-inch polyisocyanurate and one-inch wood fiber. We hired a barge with a crane to dispose of the existing roof and install the new materials.

As always, we took steep safety measures, installing a safety rail system around the entire perimeter and tying off all employees at all times. Not only was the project completed on schedule, but more importantly, there were no incidents to report.

Evergreen Solar Manufacturing Plant
Devens MA

Size: 400,000 sq. ft.

We were brought into this project by Turner Construction. They were interested in having Tecta America New England, perform the roof work for this project due to the large amount of roof work involved – 400,000 sq. ft. and the critical nature of the manufacturing facility. We installed 400,000 sq. ft. of TPO, white reflective roofing that is energy star rated. Tecta America's standard pre-job safety meeting was held with the owner, general contractor and all of the crew working on the project. All of the policies and procedures were reviewed and agreed upon. Prior to working on the roof all safety lines, guard rails and roof egress was installed. Weekly tool box meetings were held on site to discuss any issues that came up during the week and any unique safety issues that were anticipated in the following weeks throughout the project process.

The unique challenge to this project was the schedule. Tecta had to install 400,000 square feet of roofing in a short period of time. Tecta America and Turner Construction completed the project on time and on budget, getting the manufacturing facility running in less than a year.

Honda Headquarters
Clermont FL

Material/System: modular tile vegetative roof & ballasted crystalline solar panels
Size: 40,000 sq. ft. total, 7,500 sq. ft. solar
Capacity: 126kW

The Honda Headquarters facility began construction in June 2009 via Schmid Construction of Clermont, FL. This landmark LEED Platinum project features every environmental roof-top concept; reflective membrane, day lighting, solar PV, solar thermal, and a vegetative roof system. Tecta America Central Florida was contracted to provide the design build for the roofing, solar photovoltaics, and vegetative roof area. The scope of work and installation was completed in March 2010.

The grid-tied 126.88kW DC photovoltaic system was engineered with 414-305w PowerGuard self ballasting module, non-penetrating wire management system, SunPower combiner boxes, and two floor mounted SatCon inverters. The output, estimated at 470kWH of alternating current per day, would displace 10% of the facilities current demand on production days. The system is expected to off save over $18,900.00 per year at current after tax utility rates.

The most challenging aspect of the project was making sure that the layout was properly arranged so that the 7,500 sq. ft. of solar modules was installed without any shade obstructions. This was a difficult task as it required careful assessment of the ensuring that the field conditions would work with the design plan.

Hunter Panels
Lake City FL

Material/System: Thin Film Photovoltaic Roof System
Size: 15,000 sq. ft.
Capacity: 76.032kW

The Hunter Panels Facility was constructed in 2004-05 as the new home for an expanding insulation products line. This new facility was to accommodate the production of polyisocyanurate panels and composites, equipment, and stock. They determined that due to an average of 500 kW being used daily, they would need to find a renewable solution to reduce their large energy consumption.

In an effort to reduce their energy consumption, Hunter Panels decided to have a solar laminate system installed. This project was unique in that it was the first solar laminate project installed in Columbia County.

Aerojet
Rancho Cordova CA

Capacity: 3,600 kW

This project began in mid August of 2009 and was completed at the end of November, 2009. It was a 3,600 kW Ground Mounted PV Solar System, comprised of nearly 18,000 PV modules mounted on a single axis sun tracking system. This system takes up approximately 22 acres of land at Aeroject in Rancho Cordova, CA, making it the largest ground mount solar project in California. Aerojet, a rocket and missile propulsion manufacturer is a subsidiary of the aerospace and defense giant, GENCORP INC.

We were subcontracted by solar manufacturer and integrator, Solar Power Inc. (SPI), to provide the manpower to install half of the solar components including: the tracking system, SPI’s own 205 watt solar PV modules, and the wiring feeding off into the inverters. SPI had utilized our labor force on several other solar roofing projects and due to our past performance, were pleased with our ability to handle complex projects safely and finish them on-schedule and within budget.

Some of the obstacles and challenges included dealing with extremely heavy large steel components of the racking system within fractional tolerances and the lack of familiarity, as this was only the second installation of this particular tracking system in the United States. We were truly pioneering the system as we went. Constant coordination with the electrical and earthwork subcontractors was required as grading and trenching for underground conduits were ongoing. Our "apprentice electricians" performed the module to module connections and pulled over 13 miles of copper wire to complete the DC portion of the electrical work. Several craftsmen fabricated the custom designed permanent dedication plaque out of the very components of the PV system itself.

Ultimately, the installation met all budgets and timelines for costs and scheduling, leaving Aerojet pleased with the project. Phase II is now underway for another 2,400 kW.

Rockwell Automation
Milwaukee WI


Established in 1903, Rockwell Automation’s mission is to improve standards of living through increased production and sustainability. As a way to carry out this mission, Rockwell decided to incorporate a green roof on one of the roof areas atop their Global Headquarters in Milwaukee.

To successfully implement this project, Rockwell Automation enlisted the help of the Milwaukee Metropolitan Sewage District (MMSD) and F.J.A. Christiansen Roofing, a Tecta America Company. FJAC - Tecta demonstrated the stormwater management and water retention capabilities. In addition to their consulting role, FJAC-Tecta designed, installed and will continue to maintain the green roof. MMSD provided a grant to fund part of this project as the stormwater management benefits are expected to prevent the combined sewer system from overflowing, sending pollutants into Lake Michigan.

Upon project approval, construction quickly began in June of 2010 with completion in mid-October for one of the largest green roofs in the state of Wisconsin.

Certified Grocers
IL

Project Type: Re-roof
Material/System: TPO 0.60 mechanically fastened, EPDM 0.60 ballasted, and TPO 0.60 fully adhered
Size: 925,000 sq. ft.

Date Installation Began: March 1, 2010
Date Installation Completed: April 15, 2010

We told the consultant that we could complete the project within 90 days from the start. The project was complete in 45 days.

When working on a project this large it is easy to lose control over labor. The assistance of one of our Texas operations kept the project moving on time and on budget.

This is high visible project. All of the men wore hard hats safety vests and harnesses at all time. Our Safety Director made weekly safety inspections.

Each crew had two four wheelers, a Lull and two 100 yard semi dump trailers. The tear off was moved to the edge via the four wheelers. The material was taken down with the Lull and placed in the 100 yard semi dump trailers.

Coca-Cola
KY

Project Type: Re-roof
Material/System: Metal decking, two layers of 1.5" iso, and a fully adhered EPDM roof
Size: 16,300 sq. ft.

Date Installation Began: November 13, 2009
Date Installation Completed: March 1, 2010

We were originally called to the location to repair a leak. When we arrived, we found that the integrity of the roof system had been compromised by high winds. The EPDM membrane was no longer adhered to the insulation. The wind had blown the membrane up with such force that it turned pipe boots inside out, damaged drain lines, and bent counter flashing back onto itself.

The most challenging parts of this job were the set-up area and working around the deck replacement. We had to safely remove two roof systems and the decking, then install new metal decking and make the building watertight every day. Only a small space was available for set-up and dumpsters. This area would not allow for a chute, so all of the loading and unloading had to be done from a forklift.

Each day, we removed small portions of the roof to expose the decking. The decking was then cut out and replaced with metal.

E. ON US Aburndale Office Distribution West
KY

Project Type: Re-roof
Size: 50,000 sq. ft.

Date Installation Began: August 27, 2010
Date Installation Completed: November 11, 2010

The client’s issue was that the roof was leaking and they wanted to get it serviced before the new owner was to take over.

What made this a successful project was an outstanding crew. Having a foreman and superintendent who know how to set up and keep a large project like this going is the key. Additionally, daily communication with the owner’s representative was crucial to ensure all expectations were being met.

About 90% of the old roof insulation was rewrapped and hauled away for recycling. Also, E.ON/US kept about 50 tons of the ballast on their site and the rest went to a Garden Center for resale.

The new roof installation consisted of nailing a base sheet to the tectum deck, installing new insulation & one ply of base sheet in a mopping of Premium lll Asphalt, and two plies of SBS Membrane. Next, we embedded the new gravel surface in Powerply Cold Adhesive. Lastly, we spread the adhesive using our hands to make sure we applied the proper amount.

The most rewarding aspects were running the project following all safety guidelines, finishing on time, and knowing that we had completed a quality installation.

Larchmont Lofts
CA

We were referred by the material manufacturer for this project due to our past successful wall panel projects. We installed the wood framing along with composite wall panels. The most difficult aspect was that the wood wall sub straight framing and backer was neither square nor level. This required critical skimming and precise panel cutting. Nonetheless, the owner was well satisfied with the work performed.

Biscayne Condominiums
Miami FL

This was new construction project in which we were brought in due to our excellent working relationship with Pavarini Construction. We seamlessly were able to coordinate with all subcontractors during the project duration. The project was deemed successful as we had met both contractor and owner schedules on time.

Brown Residence
OH

Project Type: Re-roof
Size: 1,200 sq. ft.

Date Installation Began: October 23, 2010
Date Installation Completed: December 10, 2010

Initially, the client was planning on using several contractors for the project. However, they were confident that after several meetings with us, one contractor would better serve their needs and still give them the quality they deserved.

Three different specialty crews had to be scheduled around each other with little interruption of work. Our production manager did a tremendous job of organizing and communicating to the client the steps that needed to be done first and who and when we would be there.

This was a very detailed orientated client and we had the quality products and the right people to make their dream home a reality.

The client was impressed with our overall safety record and were surprised that no other contractor had explained safety standards to them. All OSHA guidelines were followed.

We installed GAF 30yr Timberline shingles, felt, GAF ice and watershield, Alside siding, Tyvek, Alcoa gutters, and quality edge gutter control cutter protection

The most rewarding aspect of this job is that they we got the entire project when they originally had just planned on us handling only the roof.

Cat Key Bahamas Residence


Project Type: Re-roof
Size: 6,000 sq. ft.

Date Installation Began: September 2010
Date Installation Completed: October 2010

The client owned a large old home on the Island and could not find a company that would help to solve their water intrusion problem.

We were not only able to offer a viable solution, but to also keep within their budget. Additionally, we had the personnel available with passports able to travel on short notice.

We first removed all rotten wood walls and flashing. Installed new wood and single ply flashing, pressure cleaned to remove old coating, primed and coated the entire building and installed all cap metal. This was the first time our maintenance crews performed work outside of the country.

All Tecta and OSHA safety protocols were adhered to and we had no lost time due to accidents. Any injury would have necessitated job stoppage and a new crew obtaining passports.

Elk Grove Promenade
Elk Grove CA

Project Type: New Construction
Material/System: Single-ply, standing seam metal

The expansive Elk Grove Promenade Mall showcases 12 distinct buildings with exteriors ranging from metal siding to copper flat seam panels to stucco. We installed the flat single-ply roofing-which stretches over 10 football fields-as well as all standing seam metal roofs, vertical and horizontal metal siding and all sheet metal flashings. The unique high rising copper laminated fireplace chimney will be an Elk Grove landmark for years.

Fry's Electronics
CA

Fry’s Electronics opened its doors in the Sacramento area in 2007, with a new, 20 year modified bitumen roofing expertly installed by us. We installed all of the low slope roofing, exterior metal roofing and architectural sheet metal. Our sheet metal specialists were also brought in to install decorative interior sheet metal finishings.

Crystal Mall
Waterford CT

Project Type: Roof Replacement
Material/System: EPDM
Size: 23,000 sq. ft.

Crystal Mall, anchored by stores like JC Penney, Macy’s, Sears and over 125 specialty stores including Abercrombie & Fitch, Gap, Eastern Mountain Sports, Old Navy, had a roof system that needed replacing. The current roof was 22 years old and had degraded such that it could no longer be repaired cost-efficiently. We determined, however, that our client could keep costs down by keeping the existing built-up roof system in place, along with existing insulation. We replaced the PVC roof and any saturated insulation, and installed a new EPDM system on time and within budget. As a result of the replacement, the R-value of the roof system went from R=14 to R=30, dramatically reducing energy consumption of the mall, and essentially offsetting the cost of the new roof.

Raley's Grocery
Lincoln CA

Capacity: 300 kW

Tecta America was contracted through Solar Power, Inc. to provide the installation capabilities for this 300 kW rack and panel system. The Raley’s store project comprised a 60,000 sq. ft. roof that required professional roofing expertise to locate the bar joists and service any penetrations and flashings. We were responsible for installing the stanchions, attaching the stanchions to the roof and patching the area upon installation. The project was completed in accordance with maintaining the existing Carlisle warranty for the building owner.

Milwaukee City Hall
Milwaukee WI

Project Type: Historic Restoration
Material/System: Copper sheet metal, modified bitumen
Size: 115,000 lbs. of copper

The ornate elements of the building’s German Renaissance design are especially visible in its top elevations and towers—areas that involved roofing and sheet metal work by crews. As a National Historic Landmark, original elements of the building had to be maintained or restored, including ornate and decorative panels that were worn out or missing.

Much of the work was on the iconic south tower, which rises 350 feet above the ground and which houses a 22,000-pound bell and the four faces of the clock. A steep-sloped copper-clad roof rises from the clock dormers, with a circular cupola with balustrade and lantern capping off the tower and holding the flagpole.

We replaced copper cladding, substrate and decorative elements on the smaller north tower, which also includes cupola and lantern with decorative elements, using approximately 115,000 pounds of copper on the overall project.

With crews working hundreds of feet above ground, the job became even more difficult during winter and windy months. Despite the weather, the complexity of the installation and steep working conditions, our crews remained accident-free. The building remains one of the most ornate city halls in the country.

Orange County Courthouse
Orlando FL

Project Type: Roof Replacement
Material/System: 3-ply SBS heat weld with custom fabricated metal flashings
Size: 160,000 sq. ft.

In 2004, Hurricane Charlie ripped through Central Florida and the 106 mph winds lifted the surfacing on the Orange County Courthouse’s BUR gravel roof, blasting pea gravel at every object within 300 yards. FEMA was brought in to assess the damage, of which required that 160,000 sq. ft. of roof would need to be replaced.

In December of 2006, Tecta America was awarded phase II of the Courthouse roof replacement project. In order to access the critical network of tunnels, buildings, rooms, and roof decks, members were subject to extraordinary security measures and background checks.

We conducted all work under a strict set of guidelines and procedures to ensure the safety and well-being of the public and private information. Evening work shifts mitigated these concerns and kept 14 crew members working overnight for more than a year.

The project included the removal of the existing roof system, all related metal flashings, lightning protection, and non-compliant mechanical components. It required careful attention to detail and continuous quality control, as both announced and unannounced visits from county representatives and the manufacturer were common.

The project was successfully completed in the fall of 2008. As a result, we’ve received commendation for quality in both our service and finished product from the county and they have since contracted us to conduct the first five years of planned maintenance for the facility.

City County Building
Indianapolis IN

Project Type: Roof Replacement
Material/System: 2-ply modified bitumen torch-applied
Size: 57,000 sq. ft.

The City had three unique requirements which we met: work around the Mayor’s Office and the Judge’s chamber hours; work in high-rise conditions, using the elevators to remove the old roof; and no disruption to the city’s daily operations.

The roof of this high-rise government building was at the end of its lifecycle and needed to be replaced. It required tear off, removal of the old roof, and a torch-applied 2-ply modified bitumen roof system. It demanded extensive safety requirements and close coordination with the building authority to remove old and install new materials using the freight elevator. Additionally, safety was a huge concern of the customers since this project was a high-rise building.

Tecta America was chosen because of our industry-leading safety record, skilled workmanship and close attention to detail.

Indiana Governor's Residence
Indianapolis IN

Size: 6,920

This project was a complete tear off and replacement of the slate and extensive architectural sheet metal copper roofs on the 6,920 square foot Governor’s Residence. We were chosen to perform the work due to our flexibility and skilled craftsmanship. The installation process ran smoothly and was completed on schedule.

Charlotte Douglas Airport
Charlotte NC

Project Type: Roof Replacement
Material/System: 4-ply, lightweight insulating concrete
Size: 83,000 sq. ft.

The Charlotte Douglass International Airport needed a contractor with the expertise and experience to roof the 83,000 square feet of Concourse C. And because it’s an airport, safety and security were priorities. Tecta America’s safety values fit in well with the client’s requirements and safety concerns.

By using a fall ban guardrail system, we were able to install the 4-ply and cap system with ease. To increase the value of the system for the client, we used an environmentally friendly lightweight insulating concrete in place of a polyisocyanurate or other type of disposable insulation. As a result, the airport saved money while increasing the life expectancy of the insulation.

Milwaukee Public Library Central Branch
Milwaukee WI

Material/System: Crystalline Solar Photovoltaic Roof System and Vegetated Roof
Size: 32,000 sq. ft.
Capacity: 30kW

Since it was founded in 1898, Milwaukee’s Public Library’s historic Central Library has been a source of knowledge and education for the community. Now the library can count a portion of its roof as one of those education tools, thanks to Tecta America Corp.’s installation of a vegetative roof and solar photovoltaic system.