A CentiMark Corporation Case Study: NASA - Building 110 and 103

Michoud Facility - New Orleans, LA

The Details:

At the Michoud Assembly Facility, there was over $500 million in Hurricane Katrina damages. This facility is where space shuttle external fuel tanks are manufactured. Several buildings sustained roof damage and structural damage.

Transportation was a problem due to flooded roads and washed out bridges that lead to both facilities. Helicopters and boats were the only way to transport emergency operations people to the facility while the roads were being cleared.

Two projects were identified as priority at Michoud: Building - 110 the Vertical Assembly Building - used to finish fuel cells for the space shuttle and Building 103 - the Manufacturing Facility for the fuel cells.

Several days after Hurricane Katrina, a team of CentiMark management and crews arrived to temporarily replace the roof that was blown off of Building 110. The team removed hurricane debris and installed a temporary roof on the facility. Negotiations began for the re-roofing process.

The Major Challenges at NASA:

CentiMark developed a fail-safe plan to completely remove all components of the existing roof system down to the structural steel and then build it back up. Working at a height of 230’, CentiMark removed the hurricane debris and removed and replaced 2,400 concrete panels weighing 400 pounds each at Building 110. At Building 103, the roof was torn down to the deck and replaced with a four-ply BUR (built-up) roof system.

Throughout this project, crews were held to the highest standards of quality control and safety. Each morning began with a 6:30 a.m. meeting to discuss the work that was completed the previous day and plan for the current day’s goals. With daily communication and making sure that everyone was on the same page, CentiMark crews finished the project on time, efficiently and without a reportable injury or accident.

One of the greatest challenges was to remove the planks safely to install the 18 gauge steel deck. Together, a number of CentiMark Managers designed a rooftop gantry crane with an electronic fork hoist. They then hired an engineer to draw up the specifications of the design and had it fabricated. The crane was designed to run along the I-beams, lift the planks off the perlins and place them on a four-wheel cart so the crews could haul them off. Crews also used a 500 ton crane to remove debris daily and place materials on the roof

Scope of Work on Building 110:

Working at 230’ off the ground, the job consisted of tearing off 42,000 square feet of the existing multi-layer roof system down to the concrete deck.

The deck consisted of 2,400 2’ x 9’ concrete panels - three inches thick. The crew then removed each 400 pound concrete panel and replaced them with 18 gauge metal deck. Once complete, the roof system consisted of 5/8” gypsum fire barrier, 10 mil vapor barrier, 2” ISO insulation, 1/2” OSB (plywood), low rise foam adhesive, and 60 mil fleeceback TPO.

While replacing the roof, the crews had to ensure their own safety as well as the safety of the NASA workers in the building below. Every few days the crews would secure nets under the sections of roof they were going to work on. They utilized NASA’s enormous internal crane (used to move the fuel tank) to secure these nets to the I-beam. On the roof, the crew used tripods and cables attached to the I-beams and worked off retractables.

“...You have helped us meet a very demanding schedule that will result in the space shuttle meeting its scheduled lift off time. You and your crew have provided a good quality product and have been instrumental in creating a great working environment between all the subcontractors involved in completing the roofing work. We appreciate your willingness to cooperate and make things happen. Your safety record has been most impressive. There have not been any accidents, injuries or close calls in what is certainly a dangerous environment...” Ron Okurowski, Project Manager, Corporate Quality Control Manager, Vanguard
Contractors, Inc..

About CentiMark

CentiMark is a full service commercial and industrial roofing contractor offering a full complement of roofing solutions: roof systems, emergency leak service, roof repair, maintenance programs and multiple site roof inspections. Our re-roofing services are typically on flat roofs utilizing EPDM roofs (rubber roofing), TPO, bitumen roof, spray polyurethane foam and coatings. CentiMark proudly serves North America as the largest roofing contractor with local offices in your community.