SLIDESHOW

Re-roofing CarMax Signature Metal Roof Canopies

The CarMax in Tinley Park, Illinois, a suburb of Chicago, needed its two signature entryway canopies re-roofed. The current standing seam metal roofs were aging and were experiencing some oil canning (bending). Along with the company logo, these two roofs are the most distinguishable features for each location so they need to be just right. Our mechanics fabricated new metal panels in our warehouse from pre-painted sheet metal from Berridge Manufacturing Co. Fabricating the panels ourselves using our roll former allowed us to create panels with the exact length, width, and profile we needed, and also to add low-profile, v-shaped striations as an engineering control against oil canning. We completed the job in November 2017 and it went off without a hitch.

We extend our appreciation to Merik, a building envelope consulting firm, for referring CarMax to Sentry Roof Services.

Swipe through the slides to see what we did (turn mobile device sideways for best viewing):

1.
This is what one of the two canopy roofs looked like before we began our work. You can see some paint degradation and some other signs of aging. We chose to replace the roof using Berridge sheet metal, which we had painted CarMax Blue and shipped in a coil to our warehouse in Norcross for fabrication by our mechanics (the term for metal roof specialists).
2.
Along the right edge of the canopy you can see a slight wave in the metal. This is called oil canning. It can occur when there is a difference between the surface temperature of the metal and the ambient temperature around it, which causes the metal to expand or contract, which in turn can deform the profile over time. Oil canning can be avoided by adjusting the width of the metal panels and fabricating the panels with v-shaped striations.
3.
Like other CarMax locations, the Tinley Park location has two canopies, one for the primary customer entrance and other for the secondary entrance. We worked on one canopy at a time, establishing a customer traffic safety setup with danger signs and directional signs.
4.
Our mechanics have removed the old roof and installed the first roll of underlayment, a waterproofing material, on one side of the canopy.
5.
Here the underlayment has been completely installed (other than the final piece in the next slide) and the mechanic is installing the starter strip along the ridge.
6.
Even though we install underlayment from the bottom up, we’re installing a secondary piece of underlayment along the bottom to protect against capillary action that causes water to run back up the roof for an inch or two. This extra layer functions as an ice and water shield. Those are the new panels you see in the foreground, ready to be installed.
7.
We used two personnel lifts during installation. The telescoping lift on the left is a platform lift and the one on right is a scissors lift, which has a larger platform but doesn’t maneuver as easily. OSHA and equipment regulations determine how much material and equipment you can lift at one time.
8.
The next three photos show the installation of the ridge cap. Here you can see the open ridge at the top of the canopy where the ridge cap will be installed. The silver metal pieces you see are called metal furring strips and serve as the ridge cap connection points.
9.
Here’s a close-up of a section of the ridge cap in the mechanic’s hand that’s getting ready to be installed. You can see the bead of CarMax Blue caulk running down the length of the cap. You can also see some of the underlayment has been brought up and turned over the ridge.
10.
Now the ridge cap is in place and the mechanic is putting on the final touches with the CarMax Blue sealant. You can also clearly see the striations created during fabrication. This new roof has a 20-year water tightness warranty from Berridge.
11.
The day is done and the job complete! The temperature was 18 degrees and the winds were blowing when we finished — fortunately our guys are hardy Southern boys so the Chicago-area weather was not an issue.