One of our most unique and challenging projects involved a foodservice equipment manufacturing plant. Our client was located near the Chemtool Incorporated plant, which experienced a major fire in June 2021. The client’s roof suffered significant damage from the smoldering embers carried by strong winds during the four-day blaze. Our task was to inspect over 300,000 square feet of roof to see if ash or embers from the neighboring fire had caused any damage.
Identifying the Damage
When our client reached out, they had concerns about potential damage from the hot embers and ash from the Chemtool fire. During our inspection, we found multiple areas on their flat, barrel, and canopy roofs where embers had damaged the membrane. Even small holes in a membrane can allow water to penetrate the insulation and decking of the roof.
Another potential issue we discovered was the build up of ash on the roof surface. This can eventually lead to clogged drains and scuppers when the ash mixes with rainfall, creating the potential for ponding water. Ponding not only strains the roof structure but also degrades the roofing material over time, especially where seams overlap.
Our Repair and Replacement Process
After our inspection, we provided the client with a summary of the different areas of the roof. After agreeing on the project terms and budget, our team of professional roofing contractors executed the following plan for each type of roof section affected:
- Flat Roofs:
- Removed all of the damaged membrane down to the insulation.
- Inspected the insulation beneath the membrane for moisture. We then replaced all wet insulation panels at a predetermined price.
- Where needed, a new layer of ½-inch HD insulation was installed. We then mechanically attached a 50-mil Duro-Tuff PVC roof membrane using the Rhino-Bond system.
- Barrel Roofs:
- The sections of barrel roof at the plant also featured a membrane roof system. These roofs have curved or arched panels that increase the height of the roof in certain areas.
- Once again, we removed the damaged membranes on the barrel roofs, assessed the insulation’s condition, and replaced wet areas as needed.
- After installing the ½-inch HD insulation, we mechanically attached a 50-mil Duro-Last roofing system per the manufacture’s warranty requirements.
- Front Canopy Roof:
- The process was similar for the front canopy roof, but here we used a 50mil Duro-Tuff Adhered Roofing System.
Materials and Benefits
For this project, we exclusively used Duro-Last and Duro-Tuff membranes. As one of the largest installers of Duro-Last products across Illinois and Wisconsin, our team is familiar with these products and we have the experience to attest to their durability. These materials not only provide a secure, watertight seal but also offer UV resistance and fire protection, ensuring long-lasting performance. Additionally, the Rhino-Bond system allowed us to attach the roofing membrane without penetrating the surface, which minimizes the risk of leaks at the seams.
The Results
The Chemtool fire of 2021 will go down as one of the worst commercial accidents in the history of Rockton, Illinois. While it was unfortunate that our client experienced collateral damage from this event, our existing relationship allowed us to quickly provide our roofing services. By acting quickly, we were able to prevent significant damage to the support structure of the plant’s roof and any water damage within the plant itself.
If you are searching for a trusted commercial roofer, contact HC Anderson Roofing Company today. Our commercial roofing experience and expert team are happy to discuss your needs and recommend a solution that fits your budget.