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Monumental Metal Re-Roofing Project

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Kessel Construction, Peak Award 2016, Metal Construction News, Bradford Forest Inc.

Large project drives Kessel Construction metal roofing square footage

Integrated hardwood forest products company Bradford Forest Inc. in Bradford, Pa., is a long-time customer of Kessel Construction Inc., Bradford, and the company has built all of their buildings and additions at the Bradford Forest complex. This kept the two companies in constant contact over the years, and discussions on the most recent re-roofing project started approximately 10 years ago, according to Steve Borowski, territory manager, and Tim Asinger, president of Kessel Construction.

There were many reasons for the length of time this project took before it was completed, including the economy and the cycle of the timber business. The company also had to investigate the severity of deteriorating secondary structurals, roof and wall panels, which had were determined and monitored for deterioration. "Budgets were developed and had to be contemplated in light of declining timber production/sales, etc.," Asinger adds.

The project entailed Kessel Construction to re-roof 100,000 square feet of a portion of one of the Bradford Forest buildings. To come up with the best solution for the project, discussions included budgetary pricing and idea sharing. Once started, the project took four months as Kessel Construction removed the existing MR-24 standing seam metal roof from Kansas City, Mo.-based Butler Manufacturing Co., along with gutters, downspouts and the eave strut. Borowski says new eave struts, gutters, MR-24 roof panels and trim were installed along with additional insulation. "The tear off and installation were completed in short sections since the building needed to be kept dry from the elements," Borowski explains.

Asinger says the company faced a number of challenges with the project, including safety, weather, and structural problems that needed to be corrected. The deteriorating secondaries and roof panels made for a challenging work environment, he adds, along with the weather as the seasons changed from fall into winter.

A design-build firm specializing in turnkey construction of commercial and industrial buildings, Kessel Construction was started in 1934 by William O. Kessel. He started the company during World War II after working in the oil fields of northern Pennsylvania, and in 1949 became a franchise with Butler Manufacturing, putting the company in the top 10 for longevity as a U.S. franchise.

The company is in its third generation as a Butler dealer. "Butler offers superior products in general, but the MR-24 standing seam roof system is a real game changer," Asinger says. "Re-roofing projects is an area of business development that we do focus on to help supplement our overall volume every year. Butler offers excellent products, marketing and dealer support, which helps make our job a little easier to accomplish."

Kessel Construction has been on Metal Construction News' top metal builders list for the past several years. This year, the company is being lauded for its metal roofing projects, which jumped from 20,000 square feet in 2014 to 209,000 square feet in 2015. In addition to the 100,000-square-foot Bradford Forest project, the company also completed an 87,000-square-foot metal-over-metal reroof for Danzer Services, an affiliate of Bradford Forest, and a 20,000-square-foot tear-off re-roof for the Bradford Bus Garage. While the various projects did not occur at the same time last year, Borowski says the amount of work made it challenging to adequately staff other projects, making it necessary to hire more people to assist in completing all of the company's work.

This 100,000-square-foot Bradford Forest project is the largest re-roof that Kessel Construction has ever completed. However, Borowski says Bradford Forest is looking to complete additional projects, similar in nature in the near future, and the company is also looking at other larger project opportunities.

As the company looks toward the rest of the year, Borowski says they don't have as many metal roofing projects lined up. "But, re-roof opportunities tend to be more prevalent when the building market is down, and towards autumn when companies look to get their facilities tightened up before winter," he adds.