- PROJECT LOCATION: Sydney, NE
- SQUARE FOOTAGE: 90,000
- CARLISLE APPLICATOR: Twin City Roofing
- PROJECT DURATION: 30 Days
- ROOFING SYSTEM: Carlisle SynTec Systems .090 black HotMopped FleeceBACK® AFX EPDM with Factory Applied Tape™
Known as the “World’s Foremost Outfi tter,” Cabela’s has built a solid reputation within the outdoor community by providing the most reliable products and supplies for any situation. From hunting and fishing equipment to tents, sleeping bags and ponchos, Cabela’s offers a full line of premium products that offer protection against even the harshest elements.
Unfortunately for Cabela’s, none of its products were equipped to handle a violent storm that severely damaged the roof on one of its distribution warehouses in Sydney, Nebraska, last spring. The warehouse featured a mechanically fastened, single-ply roof system that covered an old, worn out built-up roof (BUR).
The storm ripped off one-third of the existing membrane, leaving the BUR system exposed to the elements. The roof immediately began to leak and offi cials at Cabela’s knew something had to be done quickly or thousands of dollars in merchandise would be ruined. As a quick fix, Mike Allard, Cabela’s facilities construction manager hired a local roofing contractor to cover the exposed BUR with felt. Although the felt kept the building from experiencing excessive
leakage, Allard knew a more permanent solution had to be implemented. “We were under a lot of pressure to repair the roof as quickly as possible,” said Allard. “Even with the felt, the roof was leaking pretty badly and a large portion of the merchandise in the warehouse had to be moved to avoid being damaged.”
Working closely with Greg Ham of Coastal Specified Products, a Carlisle SynTec manufacturer’s representative, Allard chose to reroof the 90,000 square-foot warehouse with a 90-mil, HotMopped FleeceBACK EPDM system from Carlisle. Allard is familiar with Carlisle’s products, having used them extensively during a previous job with another national retailer.
“Carlisle was the only roofing product we specifi ed at my previous job. I am confi dent in the Carlisle brand because I know they manufacture a quality product at a competitive price,” said Allard. “We considered a number of options, but the HotMopped FleeceBACK system offered the quickest, most cost-effective
solution to our problem,” he added.
The HotMopped system provided Cabela’s with a durable roofing solution that offers the redundant protection of hot asphalt and a thick FleeceBACK EPDM membrane. Carlisle developed the HotMopped system, which utilizes a patented AFX fleece that inhibits asphalt bleed through, as an ideal recovery method for old BUR and modifi ed bitumen roof systems. To install the HotMopped system on the warehouse, Allard called on Twin City Roofing, an authorized Carlisle
applicator from Scottsbluff, Nebraska. Twin City had worked with Cabela’s in the past and has been installing Carlisle roof systems for over 20 years, so they had the knowledge and experience that Cabela’s was looking for. Because of the severity of the rooftop damage, Twin City was under extremely tight deadlines to complete the roofing project as quickly as possible. The HotMopped system was a natural fit for such deadlines because it could be installed directly overtop of the warehouse’s old BUR system.
“Cabela’s wanted to continue occupying the building during the re-roofi ng project, so we had to be as neat as possible,” said Terry Schank, president of Twin City Roofing. “If we would have removed the existing built-up roof system when we tore off the damaged membrane, there would have been a big mess within the building and operations inside would have been adversely affected.”
To minimize internal disruptions Twin City broke the roof into sections, tearing off and replacing the roof in one section before moving onto the next. Unlike many alternative roofing systems, the installation of the HotMopped system required very few steps. Twin City simply removed what was left of the damaged membrane, primed the existing BUR with cut-back asphalt primer, waited 30 to 60 minutes for the primer to dry, applied a layer of hot asphalt and laid the new FleeceBACK AFX membrane directly into the hot asphalt.
In order to complete the installation within the desired timeframe, Twin City utilized a Garlock™ 57-inch dual-path asphalt spreader for the asphalt application. Co-developed with Carlisle for use with its HotMopped systems, the Garlock spreader provides consistent coverage and a 57-inch-wide application of hot asphalt that fully adhered the 10-foot-wide membranes in just two passes.
According to Schank, the large, rectangular warehouse roof featured very few penetrations, allowing his crew to spread a large amount of asphalt in a short period of time. Compared to the traditional method of spreading asphalt with handheld mops, Schank was surprised at the increase in production due to the Garlock spreader.
“We’ve installed Carlisle’s HotMopped system in the past, but we’ve never used the Garlock spreader,” said Schank. “We were able to complete 70 to 80 squares of tear off and replacement per day. Doing it the traditional way [with mops] we would have only completed about 30 squares per day.”
Another timesaving feature of the HotMopped FleeceBACK system was Carlisle’s innovative Factory-Applied Tape (FAT™), which is standard on all FleeceBACK EPDM membranes. FAT is applied directly to the membrane in a factory-controlled setting and has been proven to reduce seaming time by 75 percent compared to traditional seaming methods. Schank said Twin City never would have fi nished the roof as quickly as they did without the FAT. “It was so easy to use. The Factory-Applied Tape allowed us to seam the membranes as soon as we laid them down, which really saved us time,” he said.
While Schank couldn’t stop raving about the ease and simplicity of the HotMopped system, Allard was impressed by how quickly the project was completed. From start to finish, the 90,000 squarefoot re-roofing project took Twin City only 30 days to complete.