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On-Site Roof Rollforming

Mcn  Kyp  Morin  Aug17 1

Potential faster installation and longer lasting product

When it comes to roofs, fewer seams and simpler delivery of materials to the rooftop makes for faster installation and a longer lasting product. Bristol, Conn.-based Morin Corp., a Kingspan Group company, has introduced an on-site roll forming process for its new Symmetry Roof Series that was road tested with almost 90,000 square feet formed on-site in Kentucky recently.

Running panels on-site is a real time saver for the installer. It offers production panels of any length without lapping them. Panels on one side of the roof were 46 feet long, while panels on the other side measured 161 feet, 2 inches in length, far too long to ship.

"For the longer panels we had 11 men on the roof," says Basil Slagle, production manager and roll former operator for Morin. "We also had three separate scissor lifts between the roll former and the eave with men on them to guide the panels to the roof because that's as close as we could get with the roll former."

The roofing series for this job was an 18-inchwide SymmeTry Roof Series panel with 2 1/2-inch legs. The 22-gauge Galvalume was a pre-painted PVDF Regal White. The panels were simply formed and pushed to the rooftop, and then walked into place.

Because the panels are a single piece, there was no panel-to-panel seaming, and zero chance for leaks. The top edge of the SymmeTry Roof Series is a mechanically seamed structural roof system that is both symmetrical and hydrostatic by design.


The Roll forming Process

Once the roll former was in place-about 100 feet from the roof eaves-three scissor lifts were rolled into place in-line between the rollformer and the roof edge. Slagle then ran a "sacrifice panel" to use as a bridge, of sorts, from the roll former to the roof. Panels going onto the roof would slide across the sacrifice panel to the roof, where crew members would carry them to a staging spot on the roof. The sacrifice panel, almost 100 feet long, was eventually recycled.

Slagle ran the shorter panels first so crew members could haul them across the ridge to the opposite side of the building. Then the longer panels were produced and set up on the near side of the building. The Regal White panels were all covered with plastic film to protect them from the red clay on the boots of the installers, who had to walk on the panels to install the batten over the seams. After the battens were installed and seamed, the plastic film was removed. Failure to remove the plastic film in a timely fashion will eventually lead to damage on the panels when the film is removed.


Seamless for the Project Manager

"The installation went great," says Nancy Mullins, senior project manager for Eastern Corp., Norcross, Ga. "We had anywhere from 12 to 17 crew members at the site at a given time. The challenges were the logistical hurdles like getting the scissor lifts in place and getting the panels to the roof and stacking them.

"We install all the panels and then come back to install the seam cap and do the seaming. We always wait to make sure everything is where it needs to be, in regard to any penetrations. We really had no issues."


Finishing up All the Details

After the panels were in place, the battens were installed and seamed around the 2 1/2-inch legs of each pan. The battens were cut to 46 feet to match the panel length for the shorter roof. To batten and seam the 161-plus foot panels, the battens were cut to 81 feet and lapped near the center.

Eastern also installed 1,100 linear feet of snow retention, the iBeam from Sno Gem Inc., McHenry, Ill. The iBeam is installed near the eaves on both sides of the roof, with the longer panels hosting a second row nearer the center of the roof. Slagle ran panels for four buildings, one attached to the main school building and three out buildings. "A lot of great coordination by Morin made it easier for the installer" says Peter Faulk, marketing manager, Morin. "I saw coordination between so many people, facilities and so many new variables. I watched as our expert staff pulled it all together, many details over many weeks. This was a fun success story for the Symmetry Roof Series to share."

Matt Martino is vice president of North American sales and marketing for Bristol, Conn.-based Morin Corp., a Kingspan Group company. To learn more, visit