American Airlines Center Roofing Project

Title: American Airlines Center Roofing Project

Award Category: Roofing

Project Address/Location

2500 Victory Ave

Dallas, Texas 75219
United States

Submitted By: Gary Nassibian

Company Info

Allana Buick & Bers

1199 S Belt Line Road
suite 100
Coppell, TX 75019
United States

214-886-9004

[email protected]

Project Description and Background: The roof replacement planning for this project began in 2020, but the COVID-19 pandemic hit and AAC management put the roof replacement project on hold. The project was rescheduled for the summer of 2021, but the pandemic pushed the NBA season well into the summer of 2021. On May 24, 2022, the Dallas Mavericks were battling the Golden State Warriors in Game 4 of the NBA Western Conference Finals in front of a national television audience. Outside the American Airlines Center (AAC), heavy storms were moving through the downtown Dallas area. The fine line between "managed outside" and "unmanaged inside rainfall" was broached for the second time in 2022. The NBA playoff game being viewed by millions of fans was halted because of a major roof leak directly over the playing floor. The delay was an unexpected and highly embarrassing interruption. Mavericks' owner, Mark Cuban, was angrily texting on his phone, knowing that this 20-minute delay of the game was an embarrassment for the Mavericks and the City of Dallas. Maverick’s owner Mark Cubans direction to the AAC management would finally push through a long-anticipated roof replacement for the arena. ABB was selected to design and manage the expedited roof replacement. We understood the unique circumstances of this project and that our work would go well beyond the technical issues. This project must accommodate site access and would be about client’s brand management! We understood the complexity and the responsibility to get it right. This complex project covered over 200,000 square feet over an occupied, high-usage public facility, with material handling, safety and schedule considerations and included several roof areas with different compatible roof systems.

Scope: Gary Nassibian of Allana Buick & Bers, Inc. (ABB) was selected to be the lead design consultant on this project. Gary and his team conducted a thorough roof assessment and project take off to evaluate the condition of the existing roofing system, which included identifying areas of moisture intrusion and deteriorated/discolored roofing materials. The new roofing systems were designed and installed according to manufacturer guidelines, the International Building Code, and best industry practices. Over 30 Quality Control inspections were conducted by the ABB team which included weekly progress reports to the Client. The A roofs (the four low slope turret corner roofs of the stadium), approximately 4,000 SF, utilized the following system installed over the existing concrete cast-in-place deck: • Base Ply: Soprema Elastophene Sanded 2.2 set in ColPly EF Adhesive. • PMMA Field Basecoat: Soprema Alsan RS 230 Field. • PMMA Fleece: Soprema Alsan RS Fleece set in the base coat. • PMMA Field Topcoat: Soprema Alsan RS 230 Field. • PMMA Finish Coat: Soprema Alsan RS 289 Textured. On the B roofs (low slope roofs on each side of the stadium), approximately 35,500 SF, contractor installed Soprema's Sopravap'r vapor barrier, two layers of 2.6" Polyisocyanurate insulation board set in insulation adhesive, then one layer of ½" VSH (Very Severe Hail) rated cover board set in insulation adhesive and covered it with the white Sentinel P200 80mil PVC adhered roof system. On the C roof (main dome roof area), approximately 135,000 SF, the team installed one layer of 1.5" Polyisocyanurate insulation board that was mechanically attached to the metal deck, new 3" Polyisocyanurate, one layer of ½" DEXcell FA 4x4 cover board VSH (Very Severe Hail) rated set in insulation adhesive, before adhering the Sentinel P200 80mil PVC cap sheet. All sheet metal flashings, copings, and edge metal were fabricated to meet ANSI-SPRI ES-1. Special attention was given to critical areas including the valley of the dome, turret roofs, roof penetrations, drains, and edge details to ensure watertightness.

Solution: Based on the initial assessment, Allana Buick & Bers, Inc. (ABB) developed contractor qualifications and a detailed scope of work to meet the client's project objectives. Our assessment included the size, material handling requirement, construction schedule, and type of roofing systems to be installed and material selection. Designing for reliability and durability, ABB reviewed various roof systems based on the building's requirements, local climate conditions, and longevity expectations. Soprema's high-quality, energy-efficient roof systems were chosen to ensure durability and sustainability for the American Airlines Center. The doomed roof valleys had a complex transition between the four-corner flat turret roofs. The original design was a PVC membrane which kept being eroded/displaced by the water drainage during rain events and the force of the water flow which would tear the PVC roof. A topping slab was added to protect the roof membrane. ABB specified a hybrid SBS Base sheet and reinforced PMMA in these locations. There are mechanical units that require service, and this type of membrane is more resistant to foot traffic. PMMA roof system is a durable solution without the removal of the topping slab, saving the client money and landfill disposal for this project and future projects. The decorative rise walls between the lower flat turret roofs to the upper dome roof had deteriorated/failed. Sealant on the pre-cast decorative wall were removed, surfaces prepped and new sealant installed. The roof drains were renovated with new clamping rings, bolts and drain accessories. The American Airlines logo on the main roof was re-established using durable Alsan RS PMMA system based on the product tenacity and UV resistance to color fading. A full 5-year workmanship warranty was issued by KPost Roofing & Waterproofing along with Soprema's 20-year Total Systems NDL warranty. KPost Roofing & Waterproofing roof "umbrella" program option was selected by the Client, which provides a regular maintenance schedule to inspect and extend the roof's life to ensure optimal performance.

Value: Responsive Crisis Management: In response to the impact of the interruption during a nationally televised NBA playoff game and the pandemic-driven delay, ABB initiated an expedited design, bidding and selection process to respond to the urgent critical need for a roof replacement during arena events. Strategic Consultant Involvement: Gary Nassibian RRC, RRO from ABB served as Senior Design Consultant, offering valuable expertise and continuity throughout the design, procurement and construction phases. His detailed roof assessment provided crucial insights into the existing roof system and prepared the foundation for a successful replacement project strategy and execution. Careful and Complex Execution: Accommodating the 90-foot height of the 390 ft variable sloped dome roof, the site use/logistics and material handling plan was devised by ABB to carefully remove existing roofing materials, safe delivery new materials and minimize disruption to the American Airlines Center event schedules. Helicopter lifts were scheduled and executed to safely load materials to the apex of the arena dome main roof. Compliance with Safety and Environmental Standards: Crews followed OSHA-required safety and PPE standards during material removal and disposed of waste in compliance with local regulations, meeting the Project Team and Client commitment to safety and environmental responsibility. Quality Installation According to Industry Standards: The new roofing system was installed according to Soprema and FM Global guidelines with onsite Soprema technical support visits, and frequent onsite Quality Control inspections by ABB monitor, Rick Dunham, RRO, REWO and Gary Nassibian to verify compliance with contract specifications and details. Tailored Roofing Solutions for Different Areas: Alternative roofing system assemblies were tailored to specific areas of the American Airlines Center, addressing the unique performance and installation requirements of each roof section (A, B, and C roofs) and the transition between different roofs and substrates. The system design demonstrated a nuanced understanding and creative approach to solve the facility's diverse needs, ensuring optimal roof system performance. Strategic Material Selection and Partnership: Partnering with KPost and Soprema, the project team delivered a durable, high-quality, energy-efficient system that met the building's requirements, local climate conditions, and longevity expectations. Transparent Communication and Scope Development: ABB's development of contractor qualifications and a detailed scope of work based on the initial assessment ensured proactive, effective and transparent communication and alignment with client expectations and project requirements. Timely and Successful Project Completion: Safely managing the complexities of the 200,000 square foot project over a high visibility, public event facility, ABB and the KPost Roofing team successfully completed the project safely, within budget (zero change orders), and within the 220-day contract schedule timeframe. Recognition and Aspiration for Excellence: In conclusion, ABB’s involvement provided critical experience and insight and added significant value by addressing urgent needs, implementing strategic solutions, verifying compliant execution, and providing durable, properly detailed system solutions with comprehensive 20-year system warranties. The successful completion of the project confirms our commitment to quality and client satisfaction. The American Airlines Center will now confidently host national and worldwide events without concern with the building enclosure’s performance.

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Additional Info: Roof Wind Uplift Design Structural Company: Walter P. Moore and Associates designer Contact Name: Justin L. Farr

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