Project: Art2Part
Gallery Roof
Location:
Description: Polyiso Insulation and TPO Roof 10,000 s.f.
Dates: September
– November 2007
9MAR02-SAT
In the beginning,
there was a windstorm, and it was a malevolent one. The three ply hot tar roof took wind like a
wing, sailing up and over the edge of the roof before being skewered by three
cast iron vent pipes. The old polyisocyanurate insulation was not adequately adhered to
the gypsum decking, allowing the wind to get up under the roofing material and
loft it skyward.

Figure 1 - Just After Morning Windstorm Deroofs 2035 Delmar Blvd, Look South from Parking Lot
(9MAR02).jpg
The damage was
severe. The roofing was adhered to the
brick parapet wall. In a tug of war, the
roofing material won and the parapet collapsed in defeat. Notice the white bubble of the Edward Jones
Dome, to the upper right of the photo.
The spherical dome on top the building in the center of the photo is the

Figure 2 - Metal-Era Coping Installation Detail
(4APR02).jpg
The entire roof
shifted, carrying with it the parapet wall.
That was not the problem. The
problem was that the I-beams encased in the parapet wall, which supported the
old window openings, rotated. That was
five (5) I-beams, most of which were over 20’ long, needing to be
replaced! The red metal structure,
below, is the gymnasium frame for the Saint Louis Gateway Classic Sports
Foundation (SLGCSF), which is under construction.

Figure 3 - Looking North Along
Parapet Wall at
The section of the
roof which survived was replaced in 2000.
It has blown off earlier. What a
disaster! The building on the left is
the Magestic Stove Lofts, center is the Robbins Law
Firm, and to the right is the Edge Lofts.

Figure 4 - 2035 Delmar Blvd Roof Looking South
(12MAR02).JPG
As a temporary
measure, blue tarps were spread out and weighted down to secure the roof. It was to prove a largely futile effort. The brown bridge building to the upper right
is the AT&T building, and the stair stepped building with the white cap is
the Edward Jones complex.

Figure 5 - View of Blue Tarps on BRITECH Roof
(16MAR02).jpg
5SEP07-WED
7SEP07-FRI
Today is the day to
put my money where my mouth is. After
discussions and a site visit from my local GAF Roofing Materials Corporation
rep, the order for roofing supplies at Crown C Supply is finalized and
officially placed. Bye, bye spiffy new
8SEP07-THU
Arrange the Metal-Era
gutters and coping, removed from the previous incarnation of the roof and not
very old anyway, in an open space where there are readily accessible.
9SEP07-SUN
Weather now looks
good till next Monday, the day on which a 60% chance of rain falls.
The crew's up prepping the roof to get it crystal clean. I stopped by the
apt. to verify a CAD file containing the latest roofing material layout. So far, so good. We are into demolition mode, having
pulled off some old coping and previous parapet wall roofing material, and
prepping the surface before gluing on Dens-Deck hardboard to the inside walls
of the parapet. We've also finished
power washing the roof. Luckily, last
night's rains helped. The big section of
the main roof was mostly clean this morning and only needed spot power washing. Enough of typing, now back to the building!
The team grills brats
for crew dinner this evening!

Figure 6 - 2007-09-08 Ted Swink,
Myron Swink + Jimmie Parker Powerwash
Roof.jpg
10SEP07-MON
The TPO roofing
membrane will envelop the parapet wall, as will the metal coping which perch
atop the parapet and ultimately cover the membrane. As the exterior of the building will
eventually be repainted, Ted Swink makes a circuit
around the top 8” or so with a can of Sherwin-Williams Cranberry Bog paint and
a brush. This will make the subsequent
exterior painting job much, much easier.
11SEP07-TUE
The roofing project
is coming along slowly. I have cleaned
the existing roof, which stays to serve as the base sheet for the new
roof. I've also pulled of the coping,
which is the metal trim covering the parapet wall (the wall which is above roof
line). I've started demolition of the
flashing, which runs from the roof up the parapet, and will get replaced.
The insulation and
roofing supplies are somewhere between
Depending on what I
find out on the status of the roofing supply shipment, and the weather
forecast, I am contemplating coming into the office on the day job next
week. Assuming that next week's round of
rain finally ends, I would store all the roofing materials inside my building
and start back on the project once it looks like I'll have a good stretch of
dry weather.
12SEP07-WED
Acquiring polyiso insulation and TPO roofing is not the end of
it. I must acquire a heat welding robot
to weld the seams for the 20 year installation specification. Discovered yesterday that
the equipment supplier isn’t set up for credit cards and doesn’t take business
checks (at least mine, as a new customer). Return today with a readily accepted
cashier’s check.
Get trained in my
fancy Swiss-made heat welding equipment too.
In theory, the device will work flawlessly and give the TPO roofing
material a perfect weld. Momentarily, I
shall trek to my electrical distributor to get another 50' of heavy duty three
phase extension cord for running the heat welding
robot. I have some details for a roof
mount fan to construct, so there is plenty to keep busy with.
14SEP07-FRI
The first delivery of
material arrives. The first few rolls of
roofing material will be cut into sections for the high wall parapet between
the old and new sections of the building, and for test strips to practice with
the heat welding equipment.

Figure 7 -
23SEP07-SUN
A
day for prep work. Complete work adhering geotextile fabric to
the underside of the gutters, to keep the tar residue from the reused gutters
from touching the new TPO roofing material.
I paid good money for the gutters, and intend for them to have a full and lengthy life directing water off my roof.
24SEP07-MON
A day for miscellaneous supplies. Stop by Harbor Freight Tools after work to
stock up on stuff.
26SEP07-WED
I scheduled a
delivery of roofing supplies for tomorrow (Thursday) morning. The long
awaiting roofing project is getting close to commencing!
27SEP07-THU
Supplies arrive in at

Figure 8 - 2007-09-27a Crown C Supply Delivers
Insulation + Roofing Materials.jpg

Figure 9 - 2007-09-27b Crown C Supply Arranges
Rooftop Delivery.jpg

Figure 10 - 2007-09-27c

Figure 11 - 2007-09-27d James Richardson,
Randolph Bradley + Travis Fulton Unstrap Rolls of TPO Roofing.jpg
28SEP07-FRI
Pick
up wood nailers from Fehlig
Brothers Box and Lumber, our local neighborhood around the corner lumber
company.
I
was supposed to be off work all September completing the roofing project, but
I’m still barely started. September’s
almost done. It looked like I was going
to get four days of rain last week. So,
I came into work at the day job. Beautiful weather instead.
Worked this Monday and Tuesday too - and the rain never
materialized. I took off again starting
this Wednesday. Lots of scattered rain, but
my window for taking time off was narrowing.
Well, the project is behind schedule already, but the weather still
looks great for the next ten days!
Yippee!
Start
tearing off the old roofing material at the parapet walls (over the roof line)
and make good progress. Of course,
didn't get close to installing the first row of roofing material, as planned,
and may not tomorrow either, but the crew is in full force and things are
moving. So far, so
good.
Four
tour busses just pulled up on
Figure 12 - 2007-09-28 Dwayne Taylor + James
Richardson Remove Parapet Wall Flashing.jpg
I
got a tractor trailer of roofing supplies delivered to my roof yesterday - very
scary, how much material was delivered.
Everyone is excited about the delivery of the supplies, save for the
boss, who is panicking at the thought of all that money tied up in insulation, which
is just sitting on the roof awaiting installation. Hours and hours and hours
of installation. Painful, arduous installation.

Figure 13 - 2007-09-28
My
roof looks almost artistic, with 4 foot cubes of insulation dotting the
surface. Is this why
large art projects are called “installations?”

Figure 14 - 2007-09-28 Ted Swink,
James Richardson, Travis Fulton, Jimmie Parker, Randolph Bradley, Dwayne Taylor
+ Myron Swink.jpg

Figure 15 - 2007-09-28 Travis Fulton, Jimmie
Parker, Ted Swink, James Richardson, Dwayne Taylor +
Myron Swink.jpg
29SEP07-SAT
Complete
still more prep work, removing the old roofing material over the parapet
walls. Now I’m committed to the project,
as the interior is exposed to the elements.
30SEP07-SUNContinue with prep work, adhering Dens-Deck backing board to the parapet walls, and building out the depth of the parapet to match that of the wood nailer on top of the parapet wall.

Figure 16 -
1OCT07-MON
Had a nice visit with our much overqualified safety
monitor, on loan from the University of California, Berkeley, who is in St.
Louis for an extended layover. We
tour the warehouse, roof and apartment.
Ted Swink grills up a crew BBQ, including
scrumptious vegan burgers to entice our guest safety monitor. Work late with Myron Swink
and Jimmie Parker. Get the first 50’ of
insulation and roofing in. A small strip
of the northwest corner of the building starts to fill it.

Figure 17 - 07-10-1 2035 Delmar Blvd Roof.jpg
3OCT07-WED
Rains in the morning, but the moisture is not significant and
burns off. Got the
first full 10' row of TPO roofing material down, which is good. Don’t finish paying the crew and am shutting
down the project until

Figure 18 - 07-10-3 2035 Delmar Blvd Roof.jpg
5OCT07-FRI
Glue
down a 10' row of polyiso insulation, one 4’ x 4’
sheet at a time. Rather than having the
crew walk down the insulation and then wait for a cure, we walk down the
insulation and weight it down with cobblestone.
Works much better, goes faster, and the crew likes the strategy better.

Figure 19 - 07-10-5 2035 Delmar Blvd Roof.jpg
6OCT07-SAT
Adhere the next 10' row of TPO roofing membrane to
the polyiso insulation. Almost at the halfway point!

Figure 20 - 07-10-6 2035 Delmar Blvd Roof.jpg
7OCT07-SUN
Just wrapped a thirteen hour day with the crew. I’m sore!
Went fairly smoothly and made good progress. We indulged in a crew BBQ – an “inner city que” - during lunch.

Figure 21 - 2007-10-07 James Richardson, Chris
Holland, Travis Fulton, Myron Swink, Ted Swink, Jimmie Parker +
8OCT07-MON
My
roofing project is progressing, although not as quickly as I expected. The preparation work required to clean off
the old parapet walls and get them ready for the new TPO roofing took quite a
bit of time. I am ascending the learning
curve, and am now doing a ten foot wide section of roofing per day. Today, a day worked out to 13 hours for me
and my crew. We just finished the
half-way point. I'm going to heat weld
the roofing material seams on Monday, in case it rains in the evening. It looks like I'll need to be out of the
office all this week completing the project.
9OCT07-TUE
The
crew's on lunch break and I'm checking weather.
Got off to a slow start mopping up after yesterday's
rain. No water damage to insulation,
just water needing to dry. Two guys had
to leave early, so we'll be content to do prep work today and hit it hard and
early tomorrow for the fifth 10' wide row of TPO roofing material.
I'll
be working late today to finish locating my roof mount fan, and getting a wood nailer installed. On
Wednesday, we hopefully will not have to work too late.
10NOV07-SAT
I
continue to make progress on the manufactory roof here in
The
4’ x 4’ panels of polyisocyanurate insulation are
glued down to the old roofing material using a special two part adhesive. Cobblestone makes a great weight to hold down
the insulation while it cures. The
adhesive sets quickly we discover. Almost too quickly.

Figure 22 - 2007-10-10a Spend Insulation
Adhesive, Insulation Panels Weighted Down with Cobblestone, and Insulation. jpg
A
roof mount electric exhaust fan will be mounted to draft the building on hot
summer days. We insert a wooden frame of
pressure treated 2” x 6” lumber into the insulation. A wooden curb to support the fan will be
strategically located atop the frame at a later date.

Figure 23 - 2007-10-10b The
Wood Frame for the Roofmount Exhaust Fan.jpg
11NOV07-SUN
The
day begins with great fanfare as local news crews arrive to cover this
momentous event of urban renew, team spirit, and civic progress.

Figure 24 - 2007-10-11a The
Local News Took Note of the Monumental Project.jpg
The
crew gathers rooftop for a team photo op.

Figure 25 - 2007-10-11 Back-James Richardson,
Travis Fulton, Randolph Bradley, Jimmie Parker, Ted Swink
& Front-Chris Holland, Myron Swink, Jojo Smittie.jpg
The
“bad” section of the roof blew off in a 2000 windstorm and was replaced. The “good” section of the roof waited until
2002 to blow off. Thus, the current
roofing project involves splicing the repaired 2000 section of the roof, which
has 1 ˝” of insulation, with the temporary roof over the 2002 section, which
has no insulation. The bridging
operation goes flawlessly.

Figure 26 - 2007-10-11b Bridging the Temporary
Hot Tar Roof with No Insulation and the Previous Two-Ply Roof.jpg
Installing
the TPO roofing material is like placing contact paper on the shelf. You peal off the backer and stick down the
contact paper. Of course, if you don’t
get things aligned just right, you have a disaster on your hands. First, we align the TPO. Next, we pull off the backer, exposing the
adhesive.

Figure 27 - 2007-10-11d Chris Holland, James
Richardson, Jojo Smittie,
Ted Swink Myron Swink,
Travis Fulton, Jimmie Parker + Randolph Bradley Pulling Plastic Backer.jpg
Finally,
we line up, raise the TPO, and do the Art2Part shimmy shuffle as we slowly roll
out the material over the insulation.

Figure 28 - 2007-10-11c Chris Holland, James
Richardson, Jojo Smittie,
Ted Swink Myron Swink,
Travis Fulton, + Jimmie Parker Unfurl TPO.jpg
Once
the material is adhered, the corners at the parapet walls are rolled in by hand
with a 2” seam roller.

Figure 29 - 2007-10-11e Jimmie Parker + Jojo Smittie Roll Out TPO over Parapet Wall.jpg
The
material is also rolled over the walls and will ultimately sit underneath the
gutters.

Figure 30 - 2007-10-11f
The newly placed TPO roofing material is
rolled out with a water filled lawn roller to settle down to the insulation and
achieve a good bond.

Figure 31 - 2007-10-11g Travis Fulton Smoothes
TPO with Water Filled Roller.jpg
Finally,
the Liester Varimat V heat
welding robot is used to create a perfect heat weld between the upper and lower
plys of TPO roofing material.

Figure 32 - 2007-10-11h Jimmie Parker, Myron Swink, Randolph Bradley + Foam Materials & Equipment
Company Rep Heatweld TPO.jpg
Rolling
out the roofing material progressed late, late into the night.

Figure 33 - 2007-10-11i Jimmie Parker Rolls Out
TPO Late Into the Night.jpg
12OCT07-FRI
Closing
in on the end of the project! Remove the
parking lot gutter, a fairly easy task as the gutter was simply slipped under
metal flashing. The flashing stays. Also prepare extension cords to enable the
new heat welding robot to be powered up.

Figure 34 -
13OCT07-SAT
Got
rained out12:45 pm. So far just light
rain. Didn’t get to
the insulation yet, so it appears more nuisance than disaster.
15OCT07-MON
Wrapped
laying down TPO at

Figure 35 -
18OCT07-THU
Land in St. Louis after a business trip to San Antonio on
the KC-135 Stratotanker Program. Lots of lighting in the air
and rain on the tarmac. A good
test of the roof!
20OCT07-SAT
Working on parapet wall with crew. Great weather. All’s well.
Moving slowly but surely on the rooftop. I’m going to do some manual heat
welding. Then will attempt to install
the parking lot gutter. Run crew payroll
at
Cut
the last metal termination bar at
21OCT07-SUN
At

Figure 36 -
Won’t
get gutters in this year, but will get heat welding in and termination bar
installed. Pay Myron Swink and Charles Wilson by

Figure 37 - 2007-10-21 Jimmie Parker Trims TPO
- Note Folds along Parapet Wall.jpg
22OCT07-MON
At
23OCT07-TUE
The
building is still dry this morning as I leave for the day job. It’s chilly out. Good thing I worked hard when the weather was
good! Lost of water
runs down the walls, so gutters are needed soonish.
4NOV07-SUN
This
is “fall back” day, when the time changes.
The crew and I set up for the day’s work at
12NOV07-MON
Right
now, the "manufactory" is in the midst of roofing construction.
The 10,000 s.f. main building sports 3" of brand
new polyisocyanurate insulation and a 60 mil TPO
roof. That all occurred in September and October. I was at
it this weekend tuckpointing the
chimney, heat welding little round circles called T-joints over the
joints in the roofing material, and wishing I had just a few more temperate
days in get the gutters in. Life would be much more convenient if I
didn't have to work during the week!
16NOV07-FRI
Continue
with prep work before adhering Dens-Deck backing board and TPO roofing material
to the high wall parapet. Call AmerenUE to get the alley lights repaired. The electric company is great, and within
hours a truck is onsite getting the lights back on! I’m impressed.
17NOV07-SAT
Cut
and glue sections of Dens-Deck backing board to the high wall parapet. The glue is probably past its expiration
date, as it is extremely difficult to squeeze out of the tubes. We celebrate success with a crew BBQ.

Figure 38 - 2007-11-17 Jimmie Parker Glues
Dens-Deck as Myron Swink Secures During Curing.jpg

Figure 39 - 2007-11-17 Myron Swink, Ted Swink + Jimmie
Parker.jpg
18NOV07-SUN
Cut
TPO roofing material to size and trial fit over the high wall parapet.
19NOV07-MON
Got TPO roofing material on the high wall parapet, as
wall as around the chimney. Work
on the expansion joint, which will allow the old and new sections of the
building to move independently of each other.
20NOV07-TUE
Roofing
progresses slowly. Will jump on the
expansion joint, then heat weld the expansion joint end seam which later gets
covered by a gutter, then complete heat welding the expansion joint, then
assess the time and where I am!
The
project begins to turn into a marathon as nightfall descends upon our hard
working crew. Pangs of hunger threaten progress. But this is not any ordinary day, for this is
the day which the St. Louis Gateway Classic Sports Foundation (SLGCSF) holds
their annual Thanksgiving banquet for the homeless. We are invited to partake, duly noting that
we well fit the profile of the intended banquet audience. The crew takes their dinners wrapped to go,
plates heaping full with turkey, dressing, mashed potato and gravy, rolls, and
greens. There is enough for several
meals in each hearty serving! Fortified,
we press on late, late into the night.
For the boss, the press runs extraordinarily late as night gradually
dawns into day.

Figure 40 - 2007-11-20 Myron Swink, Charles Wilson, Ted Swink,
Emma Blue, Jimmie Parker + Randolph Bradley Enjoy a SLGCSF Thanksgiving
Feast.jpg
21NOV07-WED
Done! At least, done for the
year. Enshroud the one corner of
the chimney I didn’t get to in a blue tarp, collect the tools, push the
scaffolding around and into the building for safe keeping, and hurriedly clean
up. Take the MetroLink
light rail to the airport to catch a