City of Haltom City
• Facility single-ply roof system with considerable roof top equipment key to interior process operations. (131,000 sq. ft. on four levels)
• Large food processing facility with specific health, safety, odor and sanitation requirements.
• Roof top equipment includes sensitive and safety concern ammonia piping system. Required Ammonia awareness training.
• Conducted investigation, planning, design and construction administration.
• Budget limitations, FM Class I & 1-90 compliance as well as odor and debris controls critical due to sensitive food process.
Conley Group was selected by State Fair Foods (a Division of Sara Lee) for investigation, materials testing, program development, design and project administration/observation services for a remediation project to replace a failing single roof system and upgrade equipment and piping support systems on the State Fair Foods facility in Haltom City, TX. The facility is a large food processing and distribution facility, which has specific health, safety, odor control and maintenance/sanitation requirements.
The facility is a high bay, slab-on grade, precast tilt wall concrete structure with mechanically attached single-ply PVC roof system. The building includes 131,085 square feet of roof system on four levels, with both precast double-tee concrete, and fluted steel roof decks.
The Owner acquired the facility in the mid-1990’s, and underwent a major conversion to modify the facility for their specific processes. The conversion included installation of a roof-mounted ammonia refrigeration system. The ammonia system including over 6,500 linear feet of processing piping, over 340 non-penetrating supports and over 130 piping penetrations through the deck.
Chronic Leakage conditions were worsened by roof deck deflection and ponding in sections of the 52’ central high bay. The Plant had experienced numerous water infiltration and leakage problems were due to physical damage from roof top traffic, “tented” membrane at rigid fasteners in the concrete deck areas and improper flashing details at walls and curbs.
Conley’s investigation/design process resolved the Owner’s phenolic foam concern, identified 63 obsolete curbs/penetrations, assessed interior protection requirements for demolition and prepared construction/life cycle costs and roof system performance analysis for replacement roof system options.
The critical design issues for this project were roof-top maintenance traffic resistance, odor management, safety, and ammonia piping support modifications. Based upon Conley’s analysis/recommendations, the Owner decided to redesign the ammonia piping support system to improve piping stability, reduce steel deck loading, improve roof constructibility and waterproofing details. The Owner selected the cold process modified bitumen roof system for better traffic resistance and service life. In addition, Conley’s Project Manager assisted the Owner with bid administration, bid evaluation and contract preparation for the two-phase project.
Conley Group provided construction administration and full time on-site construction observation of both the Phase I – Roof Replacement Project and the concurrent Ammonia Piping Support Modification work. The ammonia piping system posed significant safety hazards and required specialized Safety Hazmat training and daily planning of work activities and evacuation plans.
Phase I of the project was completed under budget and ahead of schedule without safety incident, work quality or coordination issues. Conley’s team is currently providing administration and site management on Phase II.