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Performance Driven Layouts Presented By: Thomas Allen Allen Consulting Group, Inc. Duro-last Representative IA, IL, MO 1/17/2013

Nick Orwig Holthaus Companies, Inc Master – Elite Contractor Canton, Illinois 2

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Today’s Theme Building Lay-out’s That

Create Performance

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Challenging Questions Have you heard about square footage production rates that seem unreal? Ever wonder how smaller crews install large quantities of membrane in a day?

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Challenging Questions Are you convinced that your Lay-Outs utilize all Duro-Last Technical Options assuring the most efficient Daily Production? Do you understand all Duro-Last Sheet Order Options and how they Affect Efficiency?

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Does Your Crew need to‌.

Modify Your Layouts To Create Efficiency? Or Is Crew Efficiency Created by Your Layouts?

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Are Your Days filled with Communication Problems?

“A man with a crane should be here any minute to unload.”

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QUESTION….. IF YOU COULD TAKE HOME ONE IDEA THAT WOULD INCREASE YOUR PROFITS WITHOUT INCREASING COSTS, WOULD YOU BE INTERESTED?

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Our Goal Today is to help you access the Duro-Last Options and Thought Process needed for

Increased Performance!

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Performance Driven Layouts Result In The Most

EFFICIENT Installation Time Given The Following Variables:

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Project Variables: Weather Time of Year Spec Challenges / Codes Crew Size Installation Experience Techniques Tooling Available

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Understanding the Duro-Last System Variations & Layout Options will create your Performance Driven

Competitive Edge

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Our goal with Duro-Last is to create Efficient Layouts Layouts that reduce time &

Wait Time Dollars standing around Undirected workers Labor over-runs

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Does You Crew Stand Around Waiting For Job Created Solutions?

Wait Time?

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So‌.. Where do we start To Build our Duro-Last Sheets for an

Efficient Outcome? N

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Performance Driven Thinking Process….  Define

the Existing Roof Surface  Define the Project Parameters  Define Your Work Force  Define the System to Propose  Define the Spec / Scope of Work  Define the Execution  Create The Lay-out

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Define the Roof Surface……

Type of Roofing Material

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Built up Roofing Smooth

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Ballasted BUR

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Single Ply Adhered

EPDM

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Single Ply Ballasted

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Modified Bitumen

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Polyurethane Foam

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Metal

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Existing Roof Surface 

BUR Smooth

BUR Ballasted

Single-ply Adhered

Single –Ply Ballasted

Modified Bitumen

Polyurethane Foam

Metal

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Searching for …… Compatibility….. and Preparation Steps

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Define The Project Parameters          

New Construction Recover / Re-roof Tear-Off / Removal Deck Type Insulation – type, thickness, size Metal Retrofit Obstructions / Flashings per SF Walls / height, condition, cap? Edge Detail / re-use, overlap, R&R cap Building Height

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Define Your Available Work Force A. Skill Level & Experience of each Position 1. Supervisor -- Skill Level Low 1 2 3 4 5 6 7 8 9 10 High a. Responsibilities ___________________________ __________________________________________ b. Current Performance? ______________________ __________________________________________ c. Specific area to improve / grow? ______________ T

__________________________________________

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Define Your Available Work Force 2. Foreman -- Skill Level

Low

1 2 3 4 5 6 7 8 9 10

High

a. Responsibilities ___________________________ __________________________________________ b. Current Performance? ______________________ __________________________________________ c. Specific area to improve / grow? ______________ __________________________________________

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Question ? Does Your Crew Know What to do

Without Being Told Or Are You Always

Directing Them Towards What To Do? N

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Your Crew Size

Varies By Roof type and Job Conditions Daily Goals? 

3 men, Accomplishable Goal__________

3-5 Men, Accomplishable Goal________

5-6 Men, Accomplishable Goal________

10 Men, Accomplishable Goal_________

15 Men, Accomplishable Goal_________

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Define the System to Propose  Mechanically Attached   

Ballasted Adhered Hybrid

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Mechanically Attached Folded Roll

Tab Size 3” & 6”

Standard Laps  Used for all standard applications  Standard decks; metal, wood, tectum, gypsum & concrete  Standard pull-outs required

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Folded Roll

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Mechanically Attached Roll on Tube

Tab Size 3” & 6”

All Lap Sizes  Used for cold weather Application  Seam Maximum, 25’  Improves aesthetics  Standard decks; metal, wood, tectum, gypsum & concrete  Standard pull-outs required

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Rolled on Tube 25’ Max Tab

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Mechanically Attached Roll Goods, 5’ Laps  PRE

APPROVAL required  Used for High Penetration applications  Standard decks; metal, wood, tectum, gypsum & concrete  Standard pull-outs required

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Roll Goods

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Ballasted • Gravel Mat Required • 10 Year Warranty only

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Adhered

Insulation Attachment: Insta-Stick Mech Attached

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Hybrid Installation

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Define the Scope of Work A. Preparation  Wall Preparation  Obstruction Removal  Edge Prep / Removal  Tear Off / Roof Removal T

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Define the Scope of Work B. Recover Prep    

Slip Sheet, FR-10, Visqueen, Geo Mat Fan Fold – 3/8” or ½” Recovery Board, 4 x 8 Insulation, 4 x 4, 4x8, ISO, EPS   

Weight Thickness Layers – 1, 2 or 3

Affects Installation Labor Times

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Membrane Thickness   

40 mil 50 mil 60 mil

2500’ max = 5’ laps 2000’ max = 5’ laps 1500’ max = 5’ laps

_______________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________

10’ Tabs   

40mil 50 mil 60 mil

3000’ max, 1 Rev - 1 forward 2500’ max, 1 Rev - 1 forward 2000’ max, 1 Rev - 1 forward

Increased Sq Footage is only allowable with 2 Tabs

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Three Panels, 1 Rev, 1 Forward

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10’ Tabs

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Tab Spacing

Duro-Last is a Custom House You Need it D-L can make it! 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

15” Laps with 3” tab FM corner sheet 25” Laps with 3” tab Florida approvals 28” Laps with 3” tab High wind / low pullout 36” Laps with 3” tab Custom structure attach 4’ Laps with 6” tab Pre-stressed “T”s 5’ Laps with 3” tab Current system 6’ Laps with 6” tab 6’ purlin fastening 7’ Laps with 6” tab 7’ purlin fastening 8’ Laps with 6” tab 4’ Purlin fastening 9’ Laps with 6” tab 4’6” Purlin fastening 10’ Laps with 6” tab Current speed system 5’ Purlin fastening

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Duro-Last Sheet Configuration & Verification   

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Square = Less welding Long Rectangular = More Tab Exposed Fastening Tab into Structure –  Purlin & “T” Concrete Custom Triangular – DL built Triangular - Field Cut

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Welding Quantities 100’ X 100’ Commercial Building 50’

50’

100’

100’ +

100’ = 200 LF Welding

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Welding Quantities 100’ X 100’ Commercial Building 100’ 25’

25’

25’

25’

100’

100’ +

100’ +

100’ = 300 LF Welding

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Structural Purlin Fastening Reverse to forward tab dimension Tabs 5’ oc 60”

5’

5’

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Pre-stressed “T” Slab Concrete Requires 4’ or 5’ oc lap spacing

Measure over 2’ for center of “T” to snap start line 2’ D-L Sheet

Drive reference screw from below

4’ or 5’ oc

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Custom Triangular

DL Built

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The Right Triangle Lay-out

Measure 2/3 of the height

Measure the Length

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Apply The 2/3 Rule Rotate cut-off 180 degrees

CUT HERE

Duro-Last Sheet D-L Sheet must have a 31”& 60” reverse

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The 2/3 Rule

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Triangular Project

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Custom Triangular Sheets ď Ž

DL Built

If visual, special tan triangle sheets must be laid out by CAD due to texture issues

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Reverse Tabs How Many? When? What Size? Reverse Tab Uses 

Edge - Wind tab 31”  Two are free, 31” & 59”

63”/ Full reverse for tall walls & interior sheets

31” & 91” to start inside of an obstruction, Safety Spec

Reverse 63” & 12331” ” Rev (2 Full Rev) to start 10’ from edge 5’ Reverse

125” rev on 10’ Tabs

50 / 50 Sheet, ½ of tabs reversed

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When Is a 31” Reverse a Cost? Fastener Row Quantity Comparison

75’ X 150’ Bldg 25’ X 75’ Sheets with 31” Rev & 31” lap FE. 37 Fastener Rows!

25’ X 75’ Sheets with 63” Full Rev & 63” lap FE. 30 Fastener Rows! Result = 20% Reduction N

In Tab / Gripull Labor

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Define The Execution A. Where to Start the Sheet Installation 1. What challenges to consider a. Water flow/drainage direction b. Interior Conduit c. Where are the problem areas 1. Time Killers Sheet Ending In Ponding Water _______________________ _______________________ Tabs Parallel to interior Conduit _______________________ Reverse & Forward Tab Obstructed

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Where to Start the Sheet Setting first tabs, Forward & Reverse Open space, no obstructions  Use Reverse Tabs to get to a clear area  Pull for length with a ratchet strap puller  Foreman & Technician's duty 

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Forward & Reverse - Start

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Forward & Reverse Starting Multiple Sheets

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What Determines Sheet Size? What’s Best?        T

Consider… Roof access Hoist capabilities / Crane access Existing roof penetrations Crew size Roll weight Labor easing equipment Temperature Welding Quantity

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Application Techniques Wave Approach To Installation Steps      

Repair / Edge Preparation Slip Sheet – Fan fold - Insulation Sheet Setting Sheet Installation / Completion Welding Terminating / Edging

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Define the Lay-Out -- Performance Mode -A. Create Lay-Outs that Keep Staff moving 1. Supervisor and Foreman must coordinate Crew a. Pair up experience with training personnel b. Use skilled worker in tough regions of the project c. Stage the installation steps for all to end together

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Define the Lay-Out -- Performance Mode -B. Create Deck Sheet Lay-Outs that Increase Completed SF/day 1. Non obstructed sections a. Longer tabs b. More reverse tabs c. 10’ panels 2. Obstructed roof sections a. Smaller sections b. Custom reverse tabs 3. Standard Sheets a. Discounted from DL, over 50,000 SF b. Saves time, Fewer rows of Fasteners

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Standard Sheets? Good for Duro-Last and Good for You

 

Simple Concept-------- 2.5’ increments Sheet Length--------40’- 80’ Standard Sheets have Fewer Welds That Means Fewer Tabs to Fasten! SAVES TIME!!!

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Standard Sheets, Not a Cost! But an Asset! 75’ X 150’ Bldg 25’ X 75’ Sheets with 31” Rev & 31” lap FE. 37 Fastener Rows!

25’ X 75’ Sheets with 63” Full Rev & 63” lap FE. 30 Fastener Rows! Result = 20% Reduction In Tab / Gripull Labor

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Standard Sheets Good for You When….. The last tab panel of a D-L sheet is a full 5’ or 10’ So…If an edge sheet dimension ends in 2’6” or 7’6” it needs to have a 31” rev for a full panel at the end. (22’6”, 47’6”)

Avoid 31“ rev tabs in the field and try to have your sheets end on 5 or 0…when using a full reverse (20’,25’,30’,35’,40’)

That Means Fewer Rows of Fasteners N

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Define the Lay-Out -- Performance Mode -C.

Create Deck Sheet Lay-outs that improve aesthetics 1. Start sheet in an open area 2. Work toward obstructed area 3. Work toward Cricket / Saddles

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Special Lay-out Needs Cricket transitions Recommendation: use 28� tabs out from wall to the tip of the cricket / saddle

Field Seams

D -L Sheet will make one plane change at either end of the tab or tenting results

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Special Lay-out Needs 

Barrel roof layouts

Barrel roof valleys

Note: A sloped cricket, adjacent to a curved barrel will change the angle of transition with each tab

Field Weld

Barrel valley application requires starting at low end too eliminate “tenting”

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Define the Lay-Out -- Performance Mode -D. Verify Deck Sheet Coverage 1. Add deck sheets together Should = 2. Bldg dimension + seam tolerance

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Verify Deck Sheet Coverage 120’ X 80’ Commercial Building 6”

40’ 6”

41’

40’ 6”

= 122’

41’ 6” 80’ 80’

40’ 6”

6” 6”

6” = 81’6”

6” 120’

6”

+ 2’ (laps) = 122’

81’6”

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Define the Lay-Out -- Performance Mode -E. Wall Sections / Parapets 1. Tabs Up Wall (in sheet), When?____________ 2. Adhere, When___________________________ 3. Standard Parapets, A=6, B=25, C-28, etc a. Size for a 2 man operation b. When a wall tab is required, keep “B� dimension on the wall c. Have walls create inside corners d. Break wall sections at cricket/saddle peaks T

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Tips for Lay-out 1. 2. 3. 4. 5. 6. 7.

8.

Do an X – Y axis walk of the roof Watch for unit alignment and spacing Note the slope, high and low points Lay your 300’ tape the length of the roof Note drain and scupper locations Locate the best access, set–up & hoist area If a tear-off is required, work down wind of completed area? Note the slope and depth of the cricket areas

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Job Visit Steps    

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Gather building data – Use a checklist Draw a footprint, (overview) of the roof-top Mark each large obstruction (2’ or taller) Isolate cluttered areas - Roof toward these sections Use consistent symbols within your company Flow the project  

How will the execution affect the layout Repairs? Tear-off? Water flow direction?

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Measuring Needs for Layout 

Use multiple tape measures 300’ tape  100’ tape  25’ – 30’ rigid metal tape 

Reference marking Marking spray paint  Yellow crayon  Black marker  Reference blocks 

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Remember……… Performance Is Created By How You Overcome The Obstacles that are Created by the Variables !!!

EQUATES TO

Efficient Projects

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Thank You !

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Performance Driven TACTICS!  Define

the Existing Roof Surface  Define the Project Parameters  Define Your Work Force  Define the System to Propose  Define the Spec / Scope of Work  Define the Execution  Create The Lay-out

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Performance Tactics

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Performance Tactics

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Performance Tactics

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Performance Driven Layouts  

Building Lay-out's that Create Performance

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