Contractor holding roofing materials walking on the roof of The Revington

The Revington

Contractor and TPO Roof System Meet the Challenges of Demanding New Construction Project

Project Summary

  • EverGuard® SA TPO 60-mil self-adhered membrane
  • GAF SA Vapor Retarder XL self-adhered vapor-inhibiting membrane
  • EnergyGuard Polyiso Insulation flat and tapered panels
  • EverGuard® EZ Fascia provides superior protection from wind and water penetration versus shop-fabricated roof edge

Job Details

  • Location

    Worcester, MA

  • Roof Size

    480 squares

  • Completion Date

    June 2023

About The Revington

As seen in Roofing Contractor Magazine

When plans were announced for a new construction project consisting of 228 residential apartment units with ground level retail space in the thriving Canal District in Worcester, Massachusetts, Capeway Roofing Systems jumped at the chance to install the roof system.

Based in Westport, Massachusetts, Capeway Roofing Systems was tapped by the project’s general contractor, Plumb House Inc., to install a 48,000-square-foot GAF TPO roof system over the wood and concrete deck areas of The Revington. Capeway Roofing worked closely with the GAF Technical Support team and GAF sales representative to ensure everything was specified and installed correctly.

“The TPO roof system installed on The Revington seems to be favored by many designers and installers,” notes Robert DeMelo, Project Manager, Capeway Roofing Systems. “It is a roof system that is specified for versatility, which is key for mixed-use projects. As a mixed-use building, the roofs provide a durable substrate for amenities for tenants with the right assembly and structural considerations, which contractors are seeing more building owners lean towards.”
Contractors installing SA Vapor Retarder XL on The Revington
Close-up of contractor installing GAF SA Vapor Retarder XL on a flat roof
Contractor installing EnergyGuard Polyiso Insulation on The Revington
Capeway Roofing Systems Contractors laying out EverGuard TPO on a flat roof
Contractor peeling off SA TPO for commercial roofing project
Close-up of contractors installing TPO Roof System on The Revington
Contractors applying EverGuard SA TPO on The Revington’s flat roof
Contractor laying out GAF EverGuard SA TPO at the edge of the roof
Contractor finishing TPO roof system installation at The Revington
Contractors installing SA Vapor Retarder XL on The Revington
Close-up of contractor installing GAF SA Vapor Retarder XL on a flat roof
Contractor installing EnergyGuard Polyiso Insulation on The Revington
Capeway Roofing Systems Contractors laying out EverGuard TPO on a flat roof
Contractor peeling off SA TPO for commercial roofing project
Close-up of contractors installing TPO Roof System on The Revington
Contractors applying EverGuard SA TPO on The Revington’s flat roof
Contractor laying out GAF EverGuard SA TPO at the edge of the roof
Contractor finishing TPO roof system installation at The Revington
Components of Wood Deck Roof System with GAF materials
The Challenge

The roofing portion of the project began in the fall of 2022 and was completed in June of 2023. On the concrete deck areas, the system was adhered. First the GAF SA Vapor Retarder XL was installed, followed by a GAF EnergyGuardTM Tapered Polyiso Insulation System and DensDeck® Prime, adhered with OlyBond 500TM SpotShot adhesive. The cover board was topped with GAF's 60-mil smooth EverGuard® TPO adhered with GAF EverGuard TPO Quick Spray.

On the wood decks, the flat and tapered insulation and cover board were mechanically attached before the self-adhered TPO was installed. The project required the installation of more than a half mile of GAF edge metal — GAF EverGuard® EZ Fascia — and other GAF TPO custom accessories. It also involved gutters at glass canopies, roof hatches, and a non-penetrating freestanding guardrail system; the project also utilized approximately 500 custom pre-made GAF TPO vent boots.

Challenges included the typical difficulties of a busy new construction site and some tough weather conditions. “There are multiple challenges we face when roofing buildings such as The Revington, including site logistics, working multiple pieces of equipment to get material from the staging area to the roof, numerous mobilizations, and the six roof assemblies with an 85-MPH Wind Addendum required on this project with different deck types,” DeMelo says. “We also worked through three seasons — and working in winter is never easy for contractors in New England. All of these challenges can hinder the roofing work, in addition to the constrained time for individual blocks of the building so that other trades can do their work.”

Components of Structural Concrete Roof System with GAF materials
The Solution

Safety was always top of mind. The site-specific safety plan included crane lift preparations, temporary safety railings, tie-off points along with flagging — all coordinated with the general contractor to keep all personnel working on the roof and on the ground safe at all times. These plans even included police details to use aerial lifts to complete a portion of the roofing work.

The success of the project was the result of impeccable planning and teamwork. “We look to manufacturers such as GAF and their innovative products to keep us roofing throughout all seasons allowing us to complete the project on or ahead of schedule, including their GAF EverGuard® SA TPO, which can be installed during the winter months to eliminate the flash-off time with adhesives while increasing productivity year-round,” notes DeMelo.

“Anytime we can increase productivity and decrease the workload on our employees, we’re interested, and the GAF SA Vapor Retarder XL helps us achieve those goals,” DeMelo continues. “It goes down quickly due to its 6-foot width, which helps us move onto the next step in the roof assembly and ultimately getting the task at hand done quicker.”

“This project required a lot of collaboration, and the GAF Technical Support team helped the design team on the assembly, pressures, and wind speed coverage — demonstrating GAF’s ability to support the contractor and project teams with not only products, but also expertise,” notes Dean Brown, a sales representative for GAF.

“Anytime we can increase productivity and decrease the workload on our employees, we’re interested, and the GAF SA Vapor Retarder XL helps us achieve those goals.”

Robert DeMelo
Project Manager, Capeway Roofing Systems

*NOTE: Contractors enrolled in GAF certification programs are not employees or agents of GAF, and GAF does not control or otherwise supervise these independent businesses. Contractors may receive benefits, such as loyalty rewards points and discounts on marketing tools from GAF for participating in the program and offering GAF enhanced warranties or guarantees, which require the use of GAF products. Your dealings with a Contractor, and any services they provide to you, are subject to the Contractor Terms of Use.

Featured Materials

A roll of EverGuard SA TPO Self-Adhered Roof Membrane by GAF.
EverGuard® SA TPO Self-Adhered Roof Membrane

Self-adhered roof membrane, ready to install direct from the factory

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A roll of GAF SA Vapor Retarder XL, a self-adhered vapor-inhibiting membrane.
GAF SA Vapor Retarder XL

Self-adhered vapor-inhibiting membrane

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Panel of GAF EverGuard Polyiso Insulation
EnergyGuard™ Polyiso Insulation

High thermal value panel with glass fiber reinforced cellulosic felt facers (GRF) bonded to a core of isocyanurate foam

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EverGuard EZ Fascia for commercial roofing
EverGuard® EZ Fascia

Provides superior protection from wind and water penetration versus shop-fabricated roof edge

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