Story

Disney’s Riviera Resort

General

            S&S Roofing Systems wasresponsible for the installation of over 40,000 SF of CertainTeed CarriageHouse shingles and over 6,000 SF of IMETCO Series 300 radius standing seam roofpanels.  S&S also installed fifty-two(52) pre-fabricated dormers and three (3) pre-fabricated cupolas. The multitudeof different roofing systems on the project required S&S to design custom flashingsto interface with multiple finishes.

Unique Challenges and Innovative Solutions

            S&S Roofing metthree (3) major challenges that required our project managers to strategically determinethe appropriate solution for design, access and function. Through daily andweekly meetings with the general contractor and WDI, we were able to provide functionalitywhile meeting the creative intent.

            First challenge - The shingleinstallation on the vertical radius mansard roof areas at the 11^thfloor elevation. The scaffolding provided by the general contractor forexterior elevation access did not support the roof installation nor provide accessto the roof. After careful review of the condition, it was approved to utilize rappellingto access the roof face. This required extensive training to ensure our roofinstallers were safe and technically competent. This method would also be used on the installation of other roofcomponents on this project such as the many large dormers that attached to thevertical roof sections.

            Second challenge - The installationof the fifty-two (52) pre-fabricated dormers, comprised of multiple designs andthree (3) pre-fabricated cupolas. Due to limited material staging areas, we implementeda Just-in-Time (JIT) strategy for delivery, painting and installation. A weeklyplan was developed that coordinated the crane placement and work with theevolving hardscape installation that helped facilitate hoisting the dormersinto place at the exact moment needed. The crew established the crane into the positionsit needed to support installation on the various challenging building elevations.Our installers rappelled down the roof face to fasten the dormer into the exactposition within the tight tolerance (confirmed via use of laser measuringdevices). The most detailed installation was the placement of the largestcupola over the lightning protection rod, which required the use of eight (8) taglines to precisely set the cupola into its permanent position (over 120’ aboveground).  All of this work was donewithout impact to the installed lightning protection system.

            Third challenge - The complexity ofthe radius and straight standing seam roof panel systems. These roof areas includedthe table service restaurant on the 7^th floor, multiple lowermansards, multi-tier porte cochere, overhead walkway that connected the portecochere to the main lobby area and a guard kiosk that consisted of a double radiuspanel that was curved convex and concave. Prior to the radius panelinstallations, the dormers for these radius sections of the roofs had to beinstalled.  The metal panels weredelivered as straight panels, and these panels were then shaped on site by themanufacturer’s field curving specialist and the proprietary IMETCO curvingmachine. There were multiple radiused roof areas that required each section tobe curved and installed before advancing to the next section. After the panelwas curved it was hoisted to the roof level to ensure the proper fit. Theconnector walkway proved the most challenging as it was a double radius roof (twodifferent radiuses on the same plane). This required the collective experienceof the manufacturer and S&S’s installation crews to meet the design intentof this complex element.

            Lastly,the installation of the straight standing seam roof panels on the table servicerestaurant was challenging since the hardscape was already installed below ourwork area. These materials had to be hoisted and staged to the flat roof andthen manually moved over the mansard one by one for the installation. Thecomplexity of the roof system required strategic planning and the skill of theS&S sheet metal shop. These craftsmen worked many hours to fabricate thequantity of custom fabrications required to keep the project supplied withmaterials to coordinate the installation with the schedule of the hardscape andother trades to successfully meet the overall project completion date.

Safety Efforts and Initiatives

            S&S RoofingSystems maintained a safe working environment for all of its employees. Thiswas achieved through weekly tool-box talks, completion of job hazard analysisand creation of daily pre-task plans. Prior to work each day, all tools, PPEand safety equipment were inspected for serviceability. S&S employees also participatedin the weekly project-wide safety meeting given by the general contractor. S&Sprovided its own on-site safety training for any specialized equipment toensure safe operation of all lifts, rigging and hoisting equipment.

Scheduling

            The success of this project requiredclose coordination with the other trades. On a project of this size, multiple tradesinterfaced with the roof system. This coordination proved critical to the ultimatequality of the roof system installed and in meeting the schedule. Close coordinationto note was that with the hardscape contractor (for crane access and availability)and with the electrical contractor (for advanced layout of the dormers prior toinstallation of conduit for lights that would illuminate the dormers). We also workedclosely with the framing contractor to ensure the roof deck/system met thespecified conditions and tolerances. Attendance at meetings with the generalcontractor, WDI and all the trades ensured that the roof installation movedforward in the most productive and safe manner.

Value Analysis

            The complexnature of this unique roof system required the S&S team (both management andinstallation) to be skilled in the areas of design, measurement, layout,fabrication and installation. S&S Roofing Systems has successfully trainedits crew to operate at a high level and standard for detailing, design andaccess. S&S Roofing Systems was able to successfully maintain the project schedulewhile also meeting the creative/design intent for the finished roofing product,and its high quality of craftsmanship.