Not-so common roofing

Henry C. Smither Roofing Co. installs four roof systems on The Commons


  • The plaza deck roof area work in progressPhoto courtesy of Henry C. Smither Roofing Co. Inc., Indianapolis
  • 22-gauge interlocking standing-seam galvanized steel panels were installed on the performance hall, mechanical penthouse and a portion of the playground.Photo courtesy of Henry C. Smither Roofing Co. Inc., Indianapolis
  • The vegetative areas are interspersed across various roof levels and areas visible from the nearby courthouse and office buildingsPhoto courtesy of Henry C. Smither Roofing Co. Inc., Indianapolis
  • More than 9,000 square feet of shade, extreme and evergreen plant mixes were installed to create various gardens throughout the rooftop.Photo courtesy of Henry C. Smither Roofing Co. Inc., Indianapolis

Despite its modest size, Columbus, Ind., is home to more than 80 major works of art, among them buildings designed by some of the greatest architects. Located in the heart of this architecturally sophisticated town is the newly rebuilt The Commons, a glass-enclosed, 21st century model for a community gathering place.

The structure features an indoor playground with a climber designed by architect Thomas Walker Luckey; expanded lobby showcasing a 7-ton, 30-foot-high Jean Tinguely sculpture titled "Chaos" designed and created 41 years ago when The Commons first opened; performance hall; outside terrace; giant outdoor chess board; food court; and conference room, free for use by nonprofit organizations.

The Commons originally was built in 1972 and was designed by architect Cesar Pelli as an anchor project for an ambitious downtown revitalization. In 2010, the structure was rebuilt as part of the city's Columbus Commons project, a 7-acre green space that stands on the site of the former City Center Mall. Columbus Commons was designed to be a unique, walking-friendly downtown neighborhood that integrates living spaces with retail, office and entertainment opportunities.

The preparations

The Commons building was designed by principal architect CSO Architects, Indianapolis, who collaborated with Koetter Kim and Associates, Boston, to make the public space energy-efficient and improve its usefulness as a community gathering place and performance center using technology that did not exist when Pelli designed the building.

After submitting a bid to the general contractor, Dunlap and Co., Columbus, Henry C. Smither Roofing Co. Inc., Indianapolis, was selected as the roofing contractor. Keith Romine, project manager and safety director for Henry C. Smither Roofing, was particularly pleased to work on the revitalization project.

"I grew up here," Romine says. "The original Commons is where our families shopped and children played, so to be a part of the reinvention of this remarkable space was a real honor and privilege for all of us."

The four systems

A majority of the original building was demolished except for one section that was retained in deference to Pelli.

CSO Architects' design required integration of four roof systems: polymer-modified bitumen; vegetative; plaza deck paving; and standing-seam metal.

Polymer-modified bitumen

Henry C. Smither Roofing removed the existing built-up roof system from The Commons section that was not demolished and nailed a vented base sheet over the existing tapered, lightweight concrete deck followed by insulation, a cover board and The Garland Co. Inc.'s SBS hybrid polymer-modified bitumen system applied using Type III hot asphalt.

On the new steel roof deck areas for the garden areas, tapered polyisocyanurate insulation was installed followed by The Garland Co.'s SBS hybrid polymer-modified bitumen system. The garden areas were water-tested for 48 hours to ensure flashings and other details would provide the protection demanded of high-profile public spaces.

Vegetative

More than 9,000 square feet of shade, extreme and evergreen LiveRoof® plant mixes then were installed to create various gardens throughout the rooftop. The vegetative areas are interspersed across various roof levels and areas visible from the nearby courthouse and office buildings.

Plaza deck paving

Henry C. Smither Roofing's crew applied The Garland Co.'s SBS hybrid polymer-modified bitumen system to the new concrete deck for the plaza deck roof area. The plaza deck roof area is a single level accessible from the street that features a multitude of unusual slopes, shapes and angles.

On the building's south side is an exterior public-access staircase that extends from the ground to the plaza deck roof area. The staircase had leaked water into the building's interior throughout most of the structure's history. Henry C. Smither Roofing chose The Garland Co.'s liquid-applied Dura-Walk® polyurethane coating system to prevent future leaks into the building. Precast stair treads and a paver pedestal system then were installed using Hanover® 29 3/4-inch by 29 3/4-inch Prest® pavers and custom-made tread risers along with Bison ScrewJack pedestals.

Standing-seam metal

On the performance hall, mechanical penthouse and a portion of the playground, a four-person crew installed Dimensional Metals Inc.'s 22-gauge interlocking standing-seam galvanized steel panels over Hunter Panels' Cool-Vent™ 3 1/2-inch-thick nailbase insulation with a custom 5/8-inch-thick plywood surface. Dimensional Metals' 24-gauge galvanized steel wall panels also were installed around a mechanical penthouse. Interfacing the sheet-metal elements with other roof and wall systems required careful planning.

The challenges

Because of the building's complex shapes and angles, flashing installation was a major challenge. Some counterflashing details were so low, shortening was required. The original specification also called for a TPO single-ply membrane, so modifications such as adding cant strips also were required to be modified on-site. Henry C. Smither Roofing worked closely with the architect and on-site roofing manufacturer representative to revise such details.

Working downtown also presented challenges. There virtually was no ground space to store and move materials, so truck deliveries had to be scheduled in advance and transported directly to the roof by crane.

The safety plan

The logistics of installing a roof system on a two-story structure in the middle of a busy downtown demanded the highest safety standards. Ensuring the safety of the roofing team, other subcontractors and pedestrians was a challenge Henry C. Smither Roofing took seriously.

Romine and Safety Resources Inc., Indianapolis, a safety consultant, developed a site-specific safety plan for The Commons and conducted appropriate worker training and random, independent job-site audits. A railing system was installed at perimeters, and Henry C. Smither Roofing used a combination of flagging and monitors to address the myriad of different site conditions and roofing applications that encompassed the project. The complicated work sequences took place without a hitch because of exceptional communication and a spirit of camaraderie between Henry C. Smither Roofing's team, Dunlap and Co., and the subcontractors.

"The level of support and cooperation at the job site was exceptional," Romine says. "It far surpassed what is typical of high-profile projects of comparable size and scope."

The perfect balance

The $18.5 million, 56,000-square-foot project began in July 2010 and was completed in October 2010. According to Romine, designing a building to achieve U.S. Green Building Council LEED® Silver certification standards while incorporating four roof systems makes The Commons building one of a kind.

"Columbus is known for its architecture, and I have worked with some of the best architects in the country," Romine says. "The Commons represents the pinnacle of form and function coming together in a perfect balance."

Through its revitalization, The Commons met the challenge of measuring up to the sizeable reputation of its original architect while remaining relevant in a community that still moves to the tempo of a slower, more contemplative era.

For Romine, The Commons project came full circle when he had the opportunity to play keyboard with his band in The Commons' new performance hall during his class of 1972 Columbus High School Reunion.

"For a good number of Henry C. Smither Roofing employees involved in this landmark project, the emotional connection to The Commons has been a cherished one for more than 30 years," Romine says. "With its successful reinvention, we are all looking forward to sharing this special place with a new generation of Columbus inhabitants."

For its exceptional safety efforts on The Commons, Henry C. Smither Roofing received a 2013 NRCA Gold Circle Safety Award.

Chrystine Elle Hanus is Professional Roofing's associate editor and NRCA's director of communications.


Project name: The Commons
Project location: Columbus, Ind.
Project duration: July 2010-October 2010
Roof system types: Polymer-modified bitumen, steel and vegetative
Roofing contractors: Henry C. Smither Roofing Co. Inc., Indianapolis
Product manufacturers: Bison Innovative Products, Denver; Dimensional Metals Inc., Reynoldsburg, Ohio; Hanover® Architectural Products, Hanover, Pa.; Hunter Panels, Portland, Maine; LiveRoof® LLC, Spring Lake, Mich.; The Garland Co. Inc., Cleveland
Gold Circle Awards category: Gold Circle Safety Award

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