Carderock Building 60

Bethesda, MD

Client: Naval Facilities Engineering Systems Command

Contract Value: $878,803

Expertise Highlights & Project Features: Design-Bid-Build; Exterior Renovation; Roofing; Demolition

Westerly removed and replaced a new and improved roof for Building 60, at the Carderock Naval Surface Warfare Center, in Bethesda, Maryland. This was a design-bid-build roofing project showcasing our demolition and exterior renovation skills.  Westerly provided a full comparison takeoff to the owner with the advantages and disadvantages of both cold applied and spray foam application of the roof. After determining the Spray Foam was a system better suited for dry climates, we agreed to use the cold applied roofing system, Styrene-Butadiene-Styrene (SBS) Two-Ply Roofing. Westerly was able to convey that the SBS is a strong, resilient, asphalt-modified bitumen membrane containing a core of non-woven polyester mat coated with durable SBS modified asphalt and a ceramic granule surface designed for hot mop and cold adhesive applications.. At the start of this project, Westerly developed a strategy to complete the removal and replacement of the new roof for Building 60, by section and elevation. Westerly performed several safety measures prior to beginning the project: by utilizing parapet clamps with wood railings along the perimeter of the roof for fall protection, tight scheduling with the roofing subcontractor was established to ensure water tightness and prevent leaks at the end of each work shift. Before mobilization, Westerly cleared out steel debris stationed at our contractor’s laydown area. Westerly developed a strategy to reinstall the roof, including mapping out how the project could be finished. We replaced the south (approximately 80 feet by 130 feet) and north sections housing the rooftop chillers, approximately 135‐foot by 100‐foot. The project was split into two sections: the higher roof of 10,087 square feet (south elevation) and the lower roof of 13,049 square feet (north elevation). Westerly used a fork lift to place materials on the north roof. We used a crane to raise and lower materials for the south roof, which required a crane plan, crane inspection, and NAVFAC inspection. We removed the existing built‐up 2‐ply asphalt roof system and replaced it with 3‐ply Styrene‐Butadiene‐Styrene (SBS) with cap sheet system down to the roof deck.  Westerly applied numerical values in squares for the portions of the roof to be demolished and reinstalled the same day. Mechanical roof piping was raised and re-supported during new roof installation. perform daily inspections in the mornings to identify any leaks and ensure water tightness. Weather checks were also performed to indicate days when a 30% chance of rain or snow would occur. On these weather days, no installation was performed. Westerly also performed these checks prior to starting the next section of roof installation. While working on Building 60’s roof, Westerly identified an existing wooden staircase that failed to meet code requirements. Once the assignment was complete, Westerly demolished the fragile stairs and constructed a new code compliant flight of stairs, at no additional cost to the client.