Pall Manufacturing Plant Reroof
Pensacola, Florida

The roof of the Pensacola Pall Manufacturing Plant sustained substantial damage during Hurricane Dennis in July of 2005. Portions of the existing metal edge flashing and metal roof were lost. With first hand knowledge of the effects of hurricanes on a variety of roofing systems, STOA Architects teamed with Schmidt Dell Associates and was contracted to provide the design of the 55,000 square-foot retrofit roof. The Owner defined two primary objectives for this project: Maintain operations during design and construction, and provide a roof that would sustain a Category 3 hurricane.

After completing extensive investigations of the building’s existing structural and roofing components, the design team formulated a solution which integrates the existing metal roof. Left in place, the metal roof ensured a roof over operations throughout the re-roof process. Various membrane options were presented, specified and bid, including thermoplastic, built-up roof (BUR) with modified cap sheet, and modified bituminous types. A two-ply modified bitumen roof with a 20 year, 120 mph warranty was selected as the best overall value.

Late in the design process Pall Corporation contracted with FM Global to insure their property. The roof design, which included metal bars located within the roof seams screwed into purlins below, was approved by FM Global for this application.