Ridgid Construction Case Studies: Downtown OKC Condominiums
After their condominium complex was severely damaged by hail, there were two main obstacles facing this Condo Association. The first was getting their insurance claim approved and getting a fair settlement to restore the buildings. The second was finding a contractor willing to undertake such a daunting project.
Upon first meeting with the Condo Association members, they said they had contacted several contractors to get bids in the past, but none of them ever returned. They understood why... it was a bit of a logistics nightmare. Built in downtown OKC in 1984, the complex consists of 48 units, a pool house and a swimming pool in the main courtyard, completely surrounded by 10' concrete walls. The buildings range from three to four stories high with garages below. Back in the day, the architects received accolades for designing and building such a contemporary and unique structure, but it would seem there was little consideration given in the design for future exterior maintenance and repair. Aside from being completely enclosed by a 10' concrete wall with no opening for access besides the 4' wide gates, there was very little space between structures inside. The main roofs are standing seam metal roofs with a 7:12 pitch. There are nooks and crannies everywhere with hidden roofs over balconies on every level, flat roofs, downspouts wound around corners, over and under balconies eventually running into a below ground drainage system, firewalls extend up to 20' above the roof-lines. There are catwalks, balconies, and open stairwells everywhere. In other words, just getting to the work to be done was a challenge.
Always up for a challenge, Justin (Ridgid's owner) decided to take it on. He spent a couple months analyzing, measuring, preparing estimates, meeting with the Association to discuss options and concerns, and drafting the final contract. He worked diligently with their insurance adjuster and was finally able to get the claim approved and arrive at a fair and complete claim settlement that covered all of the damage, including code upgrades. Finally, with all details worked out, Ridgid began the first phase of the restoration process.
The first order of business was fall safety! Pitched metal roofs are nearly impossible to maneuver, even with fall safety gear. Custom designed steel brackets were fabricated to apply to the high walls in order to accommodate metal fall safety lines for the painting and roofing crews to tie their harnesses off to. An OSHA approved safety plan was put in place to ensure a safe project. Temporary fencing, dumpsters, portable toilets, and equipment were set up on vacant lots we rented across the street from the complex. Occupants of the condominiums were notified that work was to begin and given an estimated schedule of projected progress.
Prior to tackling the metal roofing the concrete block walls, which were saturated with moisture due to old, peeling coatings, had to be stripped and sealed to prevent future moisture problems. During this phase of the restoration, we were contracted to do the block wall coatings on everything above the roof-lines to prevent roof leaks. They were pressure washed and scraped (and scraped and scraped) to remove the old, deteriorated coatings and expose the block enough to apply Benjamin Moore Masonry Sealer, Block Filler and the Elastomeric Coatings. This was done under the watchful eye of the Benjamin Moore rep to ensure a warrantable outcome. Once the exterior coatings were complete, the roofing process began.
The 10' concrete walls surrounding the entire complex prevented access for normal delivery of the new standing seam metal roofing material... and since all the main roofs were so pitched, they did not provide a surface to store the new roofing material once delivered. The solution? The metal roofing was lifted into the complex by crane, requiring special permits and road closures. The project was done one building at a time. Each building had a courtyard in the center, so three stories of scaffolding were set up in the courtyard of each building, providing a surface to place the material so the roofing crews had access to it. The crates were carefully numbered to facilitate situating the panels in the order they were to be installed. The old metal was torn off and manually lowered to ground level to be moved to dumpsters set up outside "the wall" for recycling. Rotted decking and fascia was removed and replaced as necessary. An upgraded underlayment of high temp ice and water shield was applied to all surfaces to provide added protection. Fascia, soffits, and gutters were installed (due to the placement of the original gutter system, they did not effectively collect water, so they were redesigned by incorporating them into the top of the fascia panels - problem solved). 24 gauge standing seam metal with Kynar/fluoropolymer finish was applied. Hundreds of feet of reglets were cut into the block to apply counterflashing to ensure no water penetration where the roofing met the walls. Modified bitumin flat roofs that were deteriorated both due to age and years of standing water since they were not pitched for runoff. They were torn out, built up for runoff and replaced with TPO roofing systems with new gutters for drainage. 8" downspouts were custom fabricated and installed, careful to stay in the same formation as the original downspouts since they ran into an underground drainage system. Wall caps were fabricated and installed at the top of the massive firewalls. Skylights were replaced. Deteriorated window jambs were replaced and resided, wood siding on areas above the roof-lines was replaced with James Hardie cement siding and painted. Finally snow guards and finishing touches were completed. Kudos to our crews who were not phased by the working conditions or plagued by a fear of heights. They literally rose to the occasion - working off of scaffolding, walk planks, ladder jacks, extension ladders, safety lines, balconies...
Many challenges presented themselves during the course of this project, but each one presented a unique opportunity to problem solve. It was very rewarding and we appreciate the opportunity. It gives a tremendous sense of satisfaction knowing how happy the residents are with their dry buildings and the major facelift we were able to help them achieve.
PROJECT MANAGER: Justin Bartusevicius
SITE FOREMAN: Juma Moss / Sue Stewart
CERTIFIED INSPECTOR - Benjamin Moore: Spectgrum Paints - K. Peters
CERTIFIED INSPECTOR - Roofing: Coates Inspections
PRODUCTS - COATINGS: Benjamin Moore Super Spec Masonry Sealer, Hi Build Block Filler, Acrylic Elastomeric
PRODUCTS - ROOFING: The Metal Store - 24 guage standing seam metal with Kynar/fluoropolymer finish
Before aerial picture of OKC Condominiums
Aerial picture of condos. As you can see, metal roofs were definitely in need of replacement
Another aerial view of condo complex shows the close proximity of the buildings and complex building configurations
View from the street shows one of the storage Pods set up for equipment.
10' walls surrounded the entire complex making access a challenge
Another view from outside the condo complex
Fenced area with storage, dumpster and portable toilet outside the wall which, along with limited space inside, didn't allow them to be placed inside where work was being done.
Material and equipment storage staged on 2 rented lots across the road from the condo complex
Before shot - pool covered to protect it from debris at Oklahoma City condos
More assessing... Gutters on original roof were situated at the bottom of the fascia so they did not collect water from roof above. Gutters were redesigned to be applied at the top of the fascia allowing them to do their job
Assessing quantity and dimensions of roofing panels needed
Assessing flashing required around the windows that sit on top of the roof
Fall safety in place enabling crews to tie off across entire expanse of roofs & walls
Another view of fall safety wire in place
Custom fabricated wall brackets secure wire for fall safety tie-offs
Custom steel brackets were fabricated for fall safety ropes
Exterior coatings above the roofs were part of this phase of renovations. Netting put in place to reduce debris when pressure washing and scraping coatings
Pressure washing exterior coatings on Bldg #1
Netting in place to keep paint chips from flying when pressure washing and scraping old coatings
Scraping loose coatings off after pressure washing
Removing old coatings in a hard to access area
Walls prepped with first coat of Benjamin Moore Concrete Sealer and Block Filler. ready for Elastomeric coating
Before pic - downspouts run around corners, over and under balconies... and down to underground drain system
Bldg #3 lower level roof before pic
One of the lower roofs on bldg 2 at OKC condos
Before pic of one of the hidden lower level, interior roofs and downspouts
Another view from courtyard
Crews tearing off old metal and manually lowering and removing it to dumpsters for recycling
Metal roof tear off complete on bldg 2 in OKC
High temp ice and water shield covers substrate before roofing is applied
Another view of high temp ice and water shield covers before roofing and fascia are applied
Another view of work in progress on bldg 2
Scaffolding set up in courtyard of bldg #2 for material staging
Scaffolding set up 3 stories high for material staging
Another pic of crane lifting material onto scaffolding set up inside - that crane operator was spot on!
Crane lifts metal roof material off the delivery truck and onto the scaffolding set up in the courtyard of bldg #2. Permits and road closures required for this endeavor
Progress being made on bldg 3 in OKC condos
Before pic of flat roofs shows how badly deteriorated they were. After pics coming soon!
One of the flat roofs before - getting ready to tear out. Flat roofs were not pitched so there was no drainage, new roofs were built up to pitch them to gutters that were added for drainage. After pics coming soon!
Before pics of rotted window jambs on 3rd story of bldg #2
In process of replacing rotted window jambs on 3rd story
Worker works off pitched metal roof to replace window jambs that were found to be leaking
Replacing window jambs and siding around them
Much better! Water tight and sided - waiting for paint
What an improvement! 3rd story windows with jambs replaced and sided with James Hardie cement siding
Working on bldg #3
View of one of the lower roofs after replacement
Working up high doing firewall caps
Fall safety equipment enables crews to work up high and hands free when necessary
Work in progress on end wall cap, siding being replaced above roof
Another view of work near completion - metal roofs, gutters, downspouts, wall caps done. Wall coatings done above roof lines as contracted for.
Bldg #2 roofing done, now for the downspouts and wall caps. Siding will be done in another phase of the project
Another view from inside - nearing completion
Getting near completion, only a few wall caps and downspouts to go
This guy obviously lost the coin toss! Replacing firewall cap on high wall
They saved this one for last, cap on high firewall completed
Getting near completion, this view shows multiple levels of metal roofs, gutters, downspouts, wall caps done. Wall coatings done above roof lines as contracted for.
Finishing touches being done on bldg #2 in OKC. Replacing the rest of the wood siding with James Hardie cement siding is the next project to be done
Pool house roof and skylights are done
View from below replacing siding on firewalls above. Also shows gutters relocated to top of fascia
View from 3rd level inside courtyard - Firewall siding replaced and wall caps being installed
Working on getting the wall caps and James Hardie siding done to complete our work for this phase of restoration
After pic, work complete for this phase of restoration. Next project - re-siding entire complex!