Harness the Wind. Build Superior Roofs.

Elkay Plastics Manufacturing Facility

Founded in 1968, Elkay Plastics is the leading US supplier of flexible packaging solutions for the food, health care and industrial markets. Elkay is committed to environmental stewardship with an established, well-documented company-wide recycling and waste minimization program.

In late summer 2017, Elkay Plastics purchased a vacant warehouse in Schaumburg, Illinois. The difficult project challenge was how to achieve a quality roof replacement, without disrupting interior renovation work and all completed by November 1. The standard roofing industry answer was either a full tear off (up to a 6 month process) with extensive interior protection, or a liquid applied coating (shorter term life expectancy). Neither solution was acceptable.

Fortunately, the WindSmart Approved Applicator determined that a third and better option was available – a WindSmart System. This unique system transfers wind uplift pressure to the structure of the building while mitigating moisture – key capabilities that are consistently approved by local code officials to achieve IBC compliance. The Approved Applicator and WindSmart worked closely with local code officials and independent design professionals to verify the engineered validity of a WindSmart system, as an accepted third roof recover application.

By September, with permit in hand, the applicator began constructing a quality roof assembly. Utilizing 30’ wide 60mil EPDM sheets, 6” seam tape and WindSmart enhanced waterproofing details to achieve an even higher quality roof assembly than was originally proposed. Start to finish (with inclement weather) a crew of only six skilled craftsman completed the WindSmart System in only six weeks. Ongoing inspections were performed by WindSmart which verified the quality and workmanship to achieve the 20 year warrantable assembly.

The new roof assembly was designed and installed to achieve:

  • Local code official’s acceptance of a WindSmart System using proprietary pressure equalization technology for code acceptance even when two roofs and/or moisture are present
  • Energy best practice in a northern climate warehouse through the utilization of dark colored membrane
  • Fast track installation process (6 weeks verses 6 months) with no internal disruption to occupants
  • Environmental Stewardship – a project aligned with the owner’s commitment to waste minimization through best practice of recycling existing roof materials and insulation in place verses the wasteful practice of premature tear off and extensive landfilling

Location:

Schaumburg, IL

Owner:

Elkay Plastics

Roofing Contractor:

WindSmart Approved Applicator

Square Footage:

304,000+ sq. ft.

Materials:

60-Mil EPDM with enhanced waterproofing details

Year Completed:

2017