Rusted Decking Case Study
The following case study highlights the hidden dangers of rusted roof decking.
Rusted Decking Case Study
The following case study highlights the hidden dangers of rusted roof decking.
Client: Millennium Maxwell House Hotel
Location: Nashville, TN
Roof Type: Built Up Roof that included multiple layers of bitumen and ply sheets alternating between layers of hot asphalt and roofing felts.
Roof Age: 46 Years
Roof Problems: Rusted Deck with Leaks and Safety Issues
Roofing Solution: Complete Tear Off
Project Overview: Millennium Hotels began a refurbishment of their properties and called in Roofing Dynamics Group for their roof inspections.
With two thick roof systems installed one on top of the other, the rusted decking was difficult to detect. The roof was at risk for collapse from heavy loads like snow or even from walking over it for routine maintenance. Unbeknownst to the owners anyone could have fallen through.
Results: Roofing Dynamics combined inspection data from our overall interior and large core/exterior visual exam of the deck, along with traditional on-the-roof infrared scans, and aerial infrared drone photography to provide a clear image of the roof system.
Our infrared scans detected temperature anomalies that indicated the probability of severely soaked insulation. Small cores confirmed the infrared readings and large coring revealed extremely rusted decking in portions of the roof.
Taken during our daily inspections, daylight photographs reveal whole steel panels rusted through. Some decking sections were torn out, some overlaid, while panels with better integrity were economically reused.
With our proper forensic methodology, we were able to provide a cost-effective solution that maximized the client’s ROI as well as save the owners a huge potential legal liability.
The Infrared Drone Survey Thermograms
The below aerial infrared images were presented to the client as part of our comprehensive report.
Area G: Blue, cool, and dry.
Area I on the South Side: blue, cool, and dry. Note heat signatures from units.
Area I North Side with Canopy to Right.
Area I North Side: Almost no significant anomalies, only reflected heat signatures.
Area I Northwest Corner: 20’ x 20’ wet free form area.
Area H: 25’ x 25’ wet corner.
Area D & E: Basically wet north side, dry south side.
Panning over 10th floor skylight: Free form patterns within lightweight pour on top. Some faint board patterns probably limited wet perlite along deckline.
Panning over 10th floor skylight: Free form patterns within lightweight pour on top. Some faint board patterns probably limited wet perlite along deckline.
Areas D and C, East End.
9th Floor Area B West Side: Some reflected heat. Basically cool, blue, and dry.
9th Floor Dead Center: Two clear thermal anomalies with the free form pattern created by water spreading out along concrete deck.
9th Floor East Side: Cool, blue, and dry.
Canopy Dead center: 25’ x 25’ wet portion close to our core, which was damp.
Infrared Survey Thermograms
The below on-the-roof infrared scans were presented to the client as part of our comprehensive report.
Reference shot: South Side 10th Floor Support Beam
Approx. 10’ x 10’ wet section on South Side
Reference shot: East Side 10th Floor
Yellow/Hot Surrounding Wet Insulation
Reverse Angle
Panning toward the Northside
Northside
Some cool/blue/dry readings but mostly soaked insulation
Close up of soaked areas
Reference shot: Air Handlers
9th Floor: Two Anomalies
9th Floor: cool/blue/dry
Daylight Inspection Photographs
The below daylight inspection photographs were presented to the client as part of our comprehensive report.
Rusted decking being replaced in the specific areas identified during our examinations.
New insulation being installed over the replaced decking areas that were damaged by rusting.
Overview of insulation installation over new decking. This daylight photo corresponds to the infrared imagery shown in this case study.
Overview of rusted deck in the targeted area.
The crewmen is properly protected from potential ACM and is harnessed in dangerous areas.
New membrane being installed over new insulation and decking.
Heat welding test strip to insure proper temperature settings.
Pieces of fragile dangerous rusted deck.
Painted side of decking from that would be seen from below, which might not look bad to the eye. Such decking could prove to be dangerous.
More decking.
More decking.
Overview of deck replacement as they overlay the new deck with the original intact deck. New insulation will be fastened and then membrane laid over top.
Working in details for installing new deck around penetrations.
Working in details for installing new deck around penetrations.
New membrane installed after deck inspection and or replacement.
After heat welding seams of roof membrane, checking quality the seam by pulling.
Tear offs are messy and intrusive and as you can see by the photos. We try to avoid tearing if possible, but sometimes it is necessary, especially when roof decking is in question.
Sometimes there are many layers during a tear off.
New field membrane and reinforced wall flashings.
New drain in roof membrane.
Overview of the new insulation and roof membrane during installation.
Overview of new watertight membrane.
Daylight Survey Photographs
The below daylight inspection photographs were presented to the client as part of our comprehensive report.
Rusted decking being replaced in the specific areas identified during our examinations.
New insulation being installed over the replaced decking areas that were damaged by rusting.
Overview of insulation installation over new decking. This daylight photo corresponds to the infrared imagery shown in this case study.
Overview of rusted deck in the targeted area.
The crewmen is properly protected from potential ACM and is harnessed in dangerous areas.
New membrane being installed over new insulation and decking.
Heat welding test strip to insure proper temperature settings.
Pieces of fragile dangerous rusted deck.
Painted side of decking from that would be seen from below, which might not look bad to the eye. Such decking could prove to be dangerous.
More decking.
More decking.
Overview of deck replacement as they overlay the new deck with the original intact deck. New insulation will be fastened and then membrane laid over top.
Working in details for installing new deck around penetrations.
Working in details for installing new deck around penetrations.
New membrane installed after deck inspection and or replacement.
After heat welding seams of roof membrane, checking quality the seam by pulling.
Tear offs are messy and intrusive and as you can see by the photos. We try to avoid tearing if possible, but sometimes it is necessary, especially when roof decking is in question.
Sometimes there are many layers during a tear off.
New field membrane and reinforced wall flashings.
New drain in roof membrane.
Overview of the new insulation and roof membrane during installation.
Overview of new watertight membrane.
Find Hidden Problems Before They Become Costly Repairs!
As an independent third-party, Roofing Dynamics is the trusted advisor you need to inform you of the true condition of your roof. Roofing Dynamics provides building owners, property managers, and facility managers accurate assessment of existing commercial roofing conditions utilizing the latest technologies with an emphasis on personal attention, quality control, and cost-effectiveness.
