The Texas Instruments RFAB Building new construction facility was a challenging project, not only to estimate but also to execute.  From the Energy Cap SBS Modified Bitumen membrane system to the multi layers insulation and PVC roof with dust control metal deck sealing, this project required creative solutions from planning through completion. The 250,000 square foot Fab roof is over a controlled environment clean room manufacturing area, which could not allow any microscopic contaminants entering through the roof system. All potential entry points were seal to create a total system envelope.

A large interest is always shown in a high profile project such as The Texas Instruments RFAB Building. As the bid date approached we analyzed the various phases and the requirements set forth in the Bid Documents to properly clarify details in the scope of work to our production team to insure proper quotes. We reviewed the scope of work to analyze all the client’s special requirements such as the LEED requirements, Factory Mutual requirements, the energy cap sheet and the energy star PVC membrane, a-typical insurance requirements, site restrictions, construction safety issues, environmental concerns and public safety interest. Out of the several bids that were submitted, Castro Roofing of Texas was selected from a list of candidates and awarded the project.
We knew from the beginning this project would be one of the most challenging new construction roofing projects to date. Due to the high profile of this project, the owner utilized several entities, including internal and external property management, in addition to an external roofing consultant to co-manage the construction.

SUBCONTRACTOR COORDINATION

Due to the job’s multi-levels and tight schedule, there was a need for coordination between the numerous subcontractors. At times it was necessary for them to work over the newly finished roof, for which Castro Roofing provided insulation to protect the new roof.
The entire project was delayed due to shortages and schedule of steel. We worked very closely with the steel subcontractor and general contractor to maintain the original schedule. To bring the project back on schedule, we increased the crew size, which enabled the schedule to be met. In fact, we helped beat the schedule by four weeks. This allowed other subs in the interior of the building to continue on working through the delay and therefore not impact the schedule.

TECHNICAL CHALLENGES 
The biggest challenge and surprise on this project was the need to seal the side and end laps of the metal deck. This requirement was not known at the time of pricing the project. Castro Roofing designed the sealing system to meet the owner’s needs to have a dust control system that would not fail after years of use.
The PVC was installed over a metal deck that required all holes, punctures and defects to be sealed with self-adhering membrane and all flutes spanned to create a virtual air tight enclosure. This is also a LEED project, which meant that all application techniques had to be met very strictly with environmental and recycle standards.
The metal deck had to be perfectly sealed; Castro Roofing recommended the use of high temperature self-adhering membrane as the dust control membrane. The deck was properly prepared and cleaned prior to installing the membrane. The membrane was installed using care not to cause any voids or wrinkles on the tight corners of the metal deck.
The ice and water shield had to be inspected daily early in the morning. Castro Roofing used the interior lights of the building to inspect for any light coming from underneath the building. After multiple inspectors approved the rigorous inspection process, the multiple layers of insulation and membrane roofing were installed.
Another challenge was the special coordination necessary to produce a finished roof to meet milestones that also allowed other trades to continue their progress. Castro Roofing at times assumed the role of Production Coordinator to facilitate overall progress and not compromise the quality of the finished roof surface due to damage or abuse from other trades. The success of this project is a result of the many different trades respecting each other’s craft to a degree that repairs and rework of damaged finished product was kept to a minimum.