Western Specialty Contractors – KC Roofing Branch installed the roof on Lenexa, Kansas’ new Kansas Commerce Center. The 140,000-sq.-ft. commercial building, located at the southwest corner of 95th Street and Twilight Lane, features office, manufacturing, storage and warehouse space.
Kansas City-based general contractor Jonkman Construction contracted with Western to install a Sika Sarnafil PVC roofing system on the building. PVC roofing systems are an affordable option for any building owner seeking long-lasting, top-of-the-line performance against ultraviolet rays, fire, ponding water and high winds.
Western’s scope of work included:
Installing a felt back PVC membrane over a poured lightweight concrete deck
Using adhesive to attach the membrane to the roof deck
Flashing walls with a self-adhered membrane
Western completed the Kansas Commerce Center roofing project in a month and a half, without delays and on budget. The architect on the project was Davidson Architecture & Engineering of Overland Park, KS.
About Western Specialty Contractors
Family-owned and operated for more than 100 years, Western Specialty Contractors is the nation’s largest specialty contractor in masonry and concrete restoration, waterproofing, and specialty roofing. Western offers a nationwide network of expertise that building owners, engineers, architects, and property managers can count on to develop cost-effective, corrective measures that can add years of useful life to a variety of structures, including industrial, commercial, healthcare, historic, educational and government buildings, parking structures, and sports stadiums. Western is headquartered in St. Louis, MO, with 30 branch offices nationwide and employs more than 1,200 salaried and hourly professionals who offer the best, time-tested techniques and innovative technology. For more information about Western Specialty Contractors, visit https://WesternSpecialtyContractors.com.
Western Specialty Contractors – Charlotte, NC Branch proudly announces it has received a 2023 International Concrete Repair Institute (ICRI) Award of Merit in the Special Projects Category for its tower modernization work at Bon Secours St. Francis Downtown Hospital in Greenville, SC.
ICRI conducts an awards program each year to honor and recognize outstanding projects in the concrete repair industry. Entries are received from around the world, and the winning projects are honored each year at the annual ICRI Awards Banquet at each ICRI Fall Convention.
The Charlotte Branch’s Bon Secours Hospital Tower Modernization project, led by general contractor Vannoy Construction, included general facade repairs, replacement of all punched windows with a new curtainwall system, and metal panel re-cladding of vertical inset areas on the hospital’s 12-story patient tower. The work was completed in 10 vertical phases over two years (12,573 workdays and 100,584 hours).
“While we may have been faced with an extremely tight schedule and multiple unforeseen conditions on this complex project, not the least of which was the COVID global pandemic, our experienced craftsmen always maintained focus, using their unique problem-solving skills to deliver a modern new façade for the hospital,” said Western Assistant Branch Manager Drew Adams. “We are so excited and honored to have our work recognized with this ICRI award.”
In January 2021, Western’s work began with demolishing 11 stories of existing masonry, a backup wall system and punched window openings at patient rooms between the masonry tiers (24,350 SF of façade demo with over 500 dumpster swaps). Crews also installed new base flashing around the perimeter of the building, saw-cut new full-height vertical expansion joints and provided new lateral anchorage along either side of the joints. Western installed new lintel head flashings above the individual tower and penthouse entry doors, with all exterior sealants at the tower wall areas removed and replaced.
Western crews installed new shelf angle flashing at each floor line (an estimated 1.1 miles) and cleaned, primed and painted any exposed steel at the masonry tiers and north core.
Western’s scope of work also included:
Demo and laying of new continuous horizontal soft joints below the shelf angle support at each floor line
Grinding and pointing all masonry mortar joints (78.6 miles of tuckpointing)
Installation of supplemental helical lateral ties at 24” on center each way
Installation of supplemental helical bed joint reinforcement at four-foot on center (2.14 miles)
Addition of supplemental mechanical lateral support between existing CMU backup walls and existing steel framing from floors 1-6
Application of a breathable penetrating clear water repellent sealer
Creation of a vertical cavity seal between masonry tier return walls and the new cladding system at window tier areas, inclusive of membrane flashing, preformed silicone and pan flashing
Western completed the project to the owner's satisfaction in December 2022 and within budget.
Family-owned and operated for more than 100 years, Western Specialty Contractors is the nation’s largest specialty contractor in masonry and concrete restoration, waterproofing, and specialty roofing. Western offers a nationwide network of expertise that building owners, engineers, architects, and property managers can count on to develop cost-effective, corrective measures that can add years of useful life to a variety of structures, including industrial, commercial, healthcare, historic, educational and government buildings, parking structures, and sports stadiums. Western is headquartered in St. Louis, MO, with 30 branch offices nationwide and employs more than 1,200 salaried and hourly professionals who offer the best, time-tested techniques and innovative technology. For more information about Western Specialty Contractors, visit https://WesternSpecialtyContractors.com.
Internationally acclaimed Australian artist Guido van Helten paints mural on restored silos
Western Specialty Contractors – Dallas, TX Branch proudly announces it has received a 2023 International Concrete Repair Institute (ICRI) Award of Excellence in the Special Projects Category for its repair/restoration of historic silos in McKinney, TX that would become the canvas for internationally-acclaimed Australian artist Guido van Helten’s US silo series, “Monuments.” McKinney’s silo mural features painted images of local business owners, gatherings and neighbors that honor the city’s culture and past. Van Helten’s public art installations can also be seen in Minnesota, Iowa, Kansas and Arkansas.
ICRI conducts an awards program each year to honor and recognize outstanding projects in the concrete repair industry. Entries are received worldwide, and the winning projects are honored each year at the annual ICRI Awards Banquet at each ICRI Fall Convention.
“This was such a large scale and important restoration project, not only for the artist but for the entire City of McKinney,” said Western Branch Manager Austin DeJohn. “We knew going into this project that these silos were not only a part of the town’s history, but they would also become the canvas for an unbelievable mural that would attract visitors from around the country. Our work would not only need to stand the test of time to preserve this historic structure, but it would also need to be restored in a way that the mural’s integrity would be protected as well. It was truly an amazing project, and we were happy to have been a part of it, and we thank the ICRI for recognizing our efforts.”
The McKinney project consisted of eight interconnected silos constructed circa 1927 as part of the Collin County Mill & Elevator Company. The mill closed in the 1970s, and the silos sat vacant for decades. The structures contributed to the mill, which was placed on the National Register of Historic Places in 1987. As part of the ongoing redevelopment of McKinney’s historic downtown, city officials desired to restore the silos to serve as a landmark and backdrop to their adjacent, new municipal complex.
Each silo is approximately 20 feet in diameter, 80 feet high and made of cast-in-place, 7-inch thick conventionally reinforced concrete walls and concrete roof slabs covered with built-up asphalt material.
The silos also featured a two-story, rectangular concrete structure, called a “doghouse,” that extended above the top of the two easternmost silos and was connected to a steel-frame structure with sheet metal siding and a roof that was centered over the remaining six silos.
Numerous cracks, delaminations and spalls were observed in the silos’ exterior walls, mainly caused by insufficient concrete cover over horizontal steel straps used for reinforcement. The cantilevered edges of the silo roofs were observed to be in poor condition, with numerous areas of spalled concrete and exposed, corroded reinforcing steel. The exterior concrete walls of the doghouse were in very poor condition, with extensive areas of spalled concrete and exposed, corroded reinforcing steel. The existing steel windows in the exterior walls were severely corroded, and there were many visible signs of freeze-thaw damage to the 6-8-inch-thick concrete walls. A steel frame had previously been installed to brace the deteriorating concrete walls and frame.
Based on the observations, testing and the intended future use of the silos by the City of McKinney, Western was contracted to perform the following scope of work:
Crack Repairs: To mitigate moisture intrusion into the concrete, cracks in the exterior concrete walls greater than 1/32-inch in width where the concrete was not delaminated were routed and sealed using a flexible polyurethane sealant. Approximately 100 feet of crack repairs were implemented.
Concrete Delamination: Spalled and delaminated concrete areas on the exterior concrete walls were removed, and exposed steel straps were cleaned and coated with a zinc-rich, epoxy-based corrosion inhibitor. Close attention was paid, ensuring conformance with ICRI Guidelines regarding surface preparation and repair geometry. The silo walls were repaired using pre-packaged polymer-modified cementitious repair mortar with an integral corrosion inhibitor. Approximately 380 cubic feet of partial-depth concrete repairs were implemented.
Roof Slab: The roof slab roofing membrane contained asbestos, and areas along the outer edges had to be abated to expose the concrete roof slabs for full assessment. Deteriorated areas of concrete slab forming the overhang were removed along with areas of deteriorated concrete on the silo walls immediately below the roof slab. Supplemental reinforcing steel was placed, anchored into the remaining roof slab with adhesive, and coated with a zinc-rich, epoxy-based corrosion inhibitor. The overhang and areas of wall repair were then formed and repaired with a pump and placed concrete. The remaining sections of the asbestos-containing roof membrane were encapsulated with a liquid-applied, two-component epoxy primer/sealer.
Roofing: Upon completion of the reconstruction of the roof overhangs, a liquid-applied polyurethane roof membrane was installed to protect the concrete roof slabs from moisture penetration. This product encapsulated the remainder of the asbestos-containing roof membrane, thus minimizing the need for hazardous material abatement.
Roof Top Doghouse: Demolition of the doghouse had to be completed before the old machinery in the doghouse could be cut up and removed. Once the roof was cleared, the floor openings from the doghouse were covered with steel plates and a new roof access hatch was installed. Approximately 12 inches of the north and south concrete walls were left in place next to the steel beams, which were located over the silo divider walls for the doghouse structure. These were retained and covered with roofing for future reconstruction of the doghouse. The opened east end of the rooftop metal shed was infilled with metal wall panels completing the work on the silo roof.
Cleaning: When repairs were completed, the walls were power washed to remove dirt and biological material, and PVC downspouts were installed so the artist could start work on the mural at the north and west elevations
Supply issues and the unforeseen difficulties encountered during the demolition of the doghouse structure compressed the construction schedule. The main objective was to complete the north and west elevations first to ensure the artist started on time. Once the north and west face of the silos were completed, work continued on the roof and the rest of the silos while the artist was installing the mural. The mural was started in June 2022 and completed in August.
Family-owned and operated for more than 100 years, Western Specialty Contractors is the nation’s largest specialty contractor in masonry and concrete restoration, waterproofing, and specialty roofing. Western offers a nationwide network of expertise that building owners, engineers, architects, and property managers can count on to develop cost-effective, corrective measures that can add years of useful life to a variety of structures, including industrial, commercial, healthcare, historic, educational and government buildings, parking structures, and sports stadiums. Western is headquartered in St. Louis, MO, with 30 branch offices nationwide and employs more than 1,200 salaried and hourly professionals who offer the best, time-tested techniques and innovative technology. For more information about Western Specialty Contractors, visit https://WesternSpecialtyContractors.com.
Western Specialty Contractors – Minneapolis Branch is nearing completion of a project to restore a masonry wall section of the Historic Wesley Church located at 101 E. Grant St. in downtown Minneapolis, MN.
The Historic Wesley Church, formerly occupied by Wesley United Methodist Church, was constructed during Minneapolis’ building boom in the 1890s. The building is made of granite, stone, brick and sandstone in the Richardsonian Romanesque style, featuring round-arched windows and multiple towers. The Preservation Alliance of Minnesota listed the church on its 2010 Most Endangered Historic Places list.
Substance Church acquired the historic Wesley building in 2016 as a permanent location. The church is located adjacent to the Minneapolis Convention Center and was once connected to a recreation center via a skyway system, which has long since been removed.
Substance Church contracted with Western in May 2023 to restore the building’s façade. Western’s scope of work includes:
Removal of the remaining skyway supports
Removal and replacement of deteriorated block wall infill, which includes plaster, clay, tile, foam insulation and concrete block
Removal and replacement of the brick facade and other wall components
Western’s craftsmen are working with Minneapolis’ Historical Society to carefully match replacement brick and mortar to the church’s original style and color to maintain its historical integrity. Western is expecting to complete the project in September 2023 within budget. Dennis Batty & Associates Group is the architect of the project.
About Western Specialty Contractors
Family-owned and operated for more than 100 years, Western Specialty Contractors is the nation’s largest specialty contractor in masonry and concrete restoration, waterproofing, and specialty roofing. Western offers a nationwide network of expertise that building owners, engineers, architects, and property managers can count on to develop cost-effective, corrective measures that can add years of useful life to a variety of structures, including industrial, commercial, healthcare, historic, educational and government buildings, parking structures, and sports stadiums. Western is headquartered in St. Louis, MO, with 30 branch offices nationwide and employs more than 1,200 salaried and hourly professionals who offer the best, time-tested techniques and innovative technology. For more information about Western Specialty Contractors, visit https://WesternSpecialtyContractors.com.
Hydronic snow melting system installed in new topping slab
Western Specialty Contractors – Denver Branch has renovated the concrete entry drive and plaza to Monroe Pointe Condominium’s underground parking garage in Denver, CO. A significant part of the renovation included the installation of a hydronic snow melting system to prevent snow and ice from accumulating on the entry drive and plaza surfaces.
Hydronic systems heat a mixture of water and propylene glycol (anti-freeze) in a centrally located water heater or boiler, which is then pumped through a network of polymer tubing embedded in concrete, asphalt or other types of medium to warm its surface. In cold climates such as Colorado, where snow and ice are prevalent, hydronic systems help to minimize damage to driving surfaces caused by traditional melting chemicals and removal equipment and make driving surfaces safer for tenants.
The Monroe Pointe Condominium Association contracted with Western’s Denver Branch and Martin & Martin Consulting Engineers to perform the work. Built in 2008, the parking garage’s concrete topping slab had passed its useful life. It was spalling, cracking and deteriorating, having been patched with concrete and asphalt multiple times over the years.
The HOA investigated many repair alternatives, which included installing a 3-inch asphalt topping or slurry coating or using precast concrete slabs to replace the deteriorating cast-in-place topping.
“We knew there was a drainage issue with the various landscape islands, so simply covering the old concrete topping slab was doomed to fail even though the old in-slab drains had been replaced. The decision was made to replace the concrete topping slab and install a snow melting system to minimize future damage,” said John Meyer, Denver Branch Project Manager.
Western started the project by removing the existing concrete topping slab and waterproofing membrane on the garage’s main entry drive and plaza. Crews then repaired the structural concrete slab as needed and installed an American Hydrotech 6125 fabric-reinforced waterproofing system, followed by the glycol/hydronic snow melting system, then finally, a new concrete topping slab.
The parking garage plaza and entry ramp are the condo’s only entry point into the parking structure. The necessary repairs and associated closures posed a real challenge for the homeowners and delivery vehicles to access the building. Through creative planning, Western was able to phase the project to allow for continuous garage use and limit the inconvenience to homeowners. Western was able to complete the project on time and within budget.
About Western Specialty Contractors
Family-owned and operated for more than 100 years, Western Specialty Contractors is the nation’s largest specialty contractor in masonry and concrete restoration, waterproofing, and specialty roofing. Western offers a nationwide network of expertise that building owners, engineers, architects, and property managers can count on to develop cost-effective, corrective measures that can add years of useful life to a variety of structures, including industrial, commercial, healthcare, historic, educational and government buildings, parking structures, and sports stadiums. Western is headquartered in St. Louis, MO, with 30 branch offices nationwide and employs more than 1,200 salaried and hourly professionals who offer the best, time-tested techniques and innovative technology. For more information about Western Specialty Contractors, visit https://WesternSpecialtyContractors.com.
New land bridge over tunnels safely reconnects park's two halves for animals and visitors
For over 50 years, Memorial Park in Houston, Texas, has been divided in half by Memorial Drive and its heavy traffic, but all that has changed. Human and animal traffic now have a seamless and safe way to enjoy both sides of the 1,500-acre park with the construction of a land bridge over recently completed vehicular tunnels.
Western Specialty Contractors – Houston Branch was tasked with waterproofing the project’s two sets of 25-foot-tall, 54-foot-wide concrete traffic tunnels that replace Memorial Drive and provide for land bridges across their tops. In August 2020, the Construction Manager at Risk Tellepsen Builders started moving dirt to facilitate the erection of 300 6-foot wide precast segments that would become the new tunnels. Waterproofing work started five months later, in January, upon the arrival of the first set of precast panels.
Western's experts applied approximately 160,000 sqft of the specified Bentonite clay waterproofing with drain mat to the tunnels' exterior walls. Bentonite is an absorbent swelling clay that is durable, long-lasting, and environmentally friendly. The waterproofing sequencing followed the installation of the precast panels, and the entire process took about 15 months to complete.
“We are so proud to have been able to play a role in this innovative project for the Memorial Park Conservancy. And while it may have been a small part of this expansive project, waterproofing plays a critical role in maintaining the longevity of concrete structures. The Bentonite clay waterproofing we applied will mitigate the risk of water intrusion and small planting roots from penetrating the tunnel through the soil backfill. Utilizing the right type of waterproofing system is vital to protecting the integrity of these underground tunnels long term,” said Western Specialty Contractors Branch Manager Brian Dolezal.
The two sets of waterproofed tunnels were then each covered with 35-foot-tall dirt mounds that became a land bridge with a network of trails for pedestrians that overlooks the park with views of the city and a greenspace covered with trees and grass for birds and other wildlife.
The new eastbound vehicle tunnels opened to traffic in March 2022, with the westbound tunnels opening in May 2022. The architect on the project was Gunda Corporation, with Walter P. Moore and Henderson Rodgers serving as the structural engineers.
About Western Specialty Contractors
Family-owned and operated for more than 100 years, Western Specialty Contractors is the nation’s largest specialty contractor in masonry and concrete restoration, waterproofing, and specialty roofing. Western offers a nationwide network of expertise that building owners, engineers, architects, and property managers can count on to develop cost-effective, corrective measures that can add years of useful life to a variety of structures, including industrial, commercial, healthcare, historic, educational and government buildings, parking structures, and sports stadiums. Western is headquartered in St. Louis, MO, with 30 branch offices nationwide and employs more than 1,200 salaried and hourly professionals who offer the best, time-tested techniques and innovative technology. For more information about Western Specialty Contractors, visit https://WesternSpecialtyContractors.com.
