Advanced Roofing undertook a monumental project in collaboration with Karins Engineering & the Vista Royale Condominium Association to rehabilitate roofs across 111 buildings. This case study delves into the meticulous planning, innovative solutions, and collaborative efforts that defined the success of the project.

Scope of Work:

The scope encompassed the rehabilitation of 107 condo buildings 4 clubhouses and repairs on one newly constructed building. Each condo building, spanning 8,766 square feet, presented unique challenges due to varying construction methods and roof conditions. Key challenges included:

• Removal of existing roofs, some with multiple layers, down to the plywood deck.
• Access into the crawl space of each unit for installation of new hurricane clips.
• Repairing damaged plywood and ensuring compliance with the current Florida Building Code.
• Designing customized solutions for each building, including 2×4 blocking and tapered Q board installation around the perimeter, to alleviate ponding at the perimeter edge of the roofs.
• Implementation of specific fastening requirements to meet Fibertite/Seaman’s 100 mph wind rider requirements.
• After attaching the Fibertite 36 mil membrane, our focus shifted to enhancing the drainage system. With precision and care, the team installed new retrofit drains, ensuring optimal water flow and protection against potential leaks.
• Additionally, Advanced Roofing performed a Tropical maintenance coating on their metal Maintenance warehouse building, which involved removing the skylights and infilling to address existing leaks.
• Replacing a cedar shake mansard at one of the Clubhouses that was deteriorated and installed a new Decra “Villa” metal tile to match the condo building mansards.

Challenges Faced:

• Material Shortage and Logistics: During a period of material shortage, Advanced Roofing had to procure larger quantities of materials earlier than usual to ensure uninterrupted progress. This necessitated the coordination of multiple tractor trailers and staging areas within an already fully occupied community.
• Discontinued Material: Towards the end of the project, the colonial red clad metal being used was discontinued. This posed a challenge as the team had to collaborate with the Engineer and Fibertite to find an acceptable alternative that matched in appearance and longevity for the remaining buildings.
• Difficult Working Conditions: Accessing the crawl space for installing hurricane straps presented challenges due to its small, dark, and hot environment. The team had to schedule this task early in the morning to mitigate discomfort.
• Limited Access: The only feasible access to certain areas was from the roof side, as there was no interior access available. This added complexity to the workflow and required careful planning.
• Recruitment for Out-of-Town Work: Finding crew members willing to live out of town for the duration of the project, which spanned three and a half years, posed a recruitment challenge for the company.
• Safety Concerns and Compliance: Some homeowners did not follow Association rules, leading to safety hazards such as improperly vented dryers that caused a safety risk. Advanced Roofing took on the responsibility of ensuring safety by inspecting every unit during the re-roofing process.
• Community Infrastructure and Safety: The lack of sidewalks in the community, combined with the presence of senior citizens walking and biking on the streets, required careful maneuvering of materials and equipment to ensure the safety of residents.

In the pursuit of community infrastructure safety, Advanced Roofing navigated the complexities of coordinating roofing efforts amidst concurrent projects such as catwalk renovations and street repaving within the Vista Royal Association. Collaborating closely with the project team, we strategically planned roofing activities in different areas to alleviate congestion and ensure efficient operations, demonstrating our commitment to the safety and well-being of the community.

• Weather Planning: The project schedule was planned around weather conditions to minimize interruptions to residents’ daily lives. Advanced Roofing scheduled work during the dry season and avoided rainy periods to optimize efficiency and minimize onsite presence.

The meticulous attention to detail didn’t stop there. Understanding the importance of both functionality and aesthetics, Advanced Roofing meticulously crafted and installed custom colonial red Kynar edge metal. Each piece was expertly designed to seamlessly blend with the structure while providing durable protection against the elements.

Project Execution:

The project was executed in five phases, each comprising 22 to 23 buildings. Given the distance from the office, the crew resided near the job site during the week. The evolving COVID-19 situation posed logistical challenges, including limited parking and staging areas due to fluctuating occupancy levels. However, meticulous planning ensured efficient staging and execution:

• Material and equipment were staged centrally and moved to individual buildings as work progressed.
• Limited parking spaces near buildings were optimally utilized for equipment and material handling.
• Specialized equipment, including a 10k lull and a 30-yard dumpster, efficiently facilitated tear-off and material loading.
• Despite the challenges, the project maintained a consistent timeline of approximately one week per building.

Acceleration and Budget Management:

Toward the project’s conclusion, acceleration was necessary to meet insurance renewal deadlines and save the association significant costs. Additional resources were deployed, including an extra crew and rented accommodations, to expedite work without compromising quality. Remarkably, the project remained within budget, with no change orders except for an additional roof added to the scope.

Safety and Quality Assurance:

Safety was paramount throughout the project, resulting in zero safety incidents. Adherence to industry standards and regulations ensured the quality and durability of the installed roofs. Regular inspections and quality checks were conducted to uphold the highest standards of workmanship.

Conclusion:

The roof rehabilitation project stands as a testament to effective project management, innovative problem-solving, and unwavering commitment to quality and safety. By overcoming logistical challenges, accelerating timelines, and staying within budget, the project not only restored the structural integrity of the buildings but also enhanced their resilience against adverse weather conditions. It also saved the Association hundreds of thousands of dollars in insurance premiums for having newly installed roofs enhanced to the High-Velocity Hurricane Zone Code.

Advanced Roofing implemented a highly systematic approach, enabling us to efficiently complete each building and seamlessly transition to the next without encountering any delays throughout the entirety of the project. This systematic approach involved meticulously planned look-ahead schedules. Moreover, we ensured compliance with all inspections, as each building required a separate permit. Working closely with Fibertite, we conducted finals for every set of five completed buildings, allowing us to promptly address any outstanding issues and progress smoothly toward project completion.

The successful completion of the project underscores the collaborative efforts of the project team and their dedication to exceeding client expectations.

Client Satisfaction Feedback:

We had a phenomenal team with unparalleled teamwork. The Engineer was onsite daily, conducting meticulous inspections. The Property Management and office staff went above and beyond, coordinating with all residents to ensure they were informed about our work on each building. The Maintenance staff played a crucial role in securing all necessary staging areas, and the Board met bi-weekly, contributing to the swift progress of the project.