Providing state-of-the-art roofing systems is second nature to Architectural Building Components, a Houston-based manufacturer of metal roofing solutions. However, when the task involves retrofitting a prison roof with nearly 1,500 convicted criminals interacting just below, the project becomes much less commonplace.
When the existing 110,000-square foot, 18-gauge galvanized standing-seam panel roof failed at C.T. Terrell Prison due to rust and perforation of the metal, officials from the Texas Department of Criminal Justice turned to Richardson, Texas-based roof consultant Amtech Building Sciences and Architectural Building Components to provide a long-lasting, watertight solution for the 27-year-old facility in Rosharon, Texas.
Besides the obvious restrictions of working in a prison, there were several unique challenges on this project. For starters, the existing roof was spanning bar joists 10 feet on center, making the process of attaching the new roof to the old structure even more difficult. To help come up with an economical solution that would meet the 120 mph design pressures, Terry Wolfe of Force Engineering
& Testing, Humble, Texas, was brought into the project. His solution was to attach the existing 18-gauge roof to the structural bar joists and use the top of the 18-gauge panel ribs as an attachment point for the 16-gauge hat sections. The new roof system would then be attached to the hat sections at a standard 5 feet on center.
“We knew our superior 238T roofing system was an ideal option for this job because of its unsurpassed wind-uplift resistance, unlimited thermal movement and outstanding static-water performance,” says Charlie Smith, president of Architectural Building Components. “The client was drawn to this product because of its unmatched wind uplift performance on an open frame, as well as the 238T’s symmetrical design that allows for individual panel repair-ability and replace-ability.”
Architectural Building Components and installer, Dallas-based Supreme Systems Inc., began to work on the Terrell Prison in September, and was on schedule for a late December completion date. The speed of the installation process was positively impacted by the 238T’s symmetrical design and by its unique ability to infill or skip an area on the roof to be installed at a later date.
Architectural Building Components manufactured 181-foot panels of 24-gauge, Galvalume Plus Steel on-site using its unique Archzilla job-site production truck, which produces panels of unlimited length onto the roof for installation.
The 110,000-square-foot project was especially challenging due to the stringent security requirements inherent while working on an active prison roof. For example, all individuals representing both Architectural Building Components and Supreme Systems had to pass extensive background checks prior to beginning work. Installers are required to wear specific clothing that differentiates themselves from the inmates; and all vehicles and materials entering and leaving the job site must be meticulously inspected to ensure that illegal items are not smuggled into or out of the facility.
From complying with rigorous top-security standards to ensuring the very best, watertight solution for the prison, Architectural Building Components is effectively covering the criminals-one seamless panel at a time.
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To learn more about Houston-based Architectural Building Components, visit www.archmetalroof.com.
