FM_Scharff_CMS 6x9 9/21/00 2:04 PM Page i ROOFING HANDBOOK Robert Scharff (Deceased) Terry Kennedy Second Edition McGraw-Hill New York San Francisco Washington, D.C. Auckland Bogotá Caracas Lisbon London Madrid Mexico City Milan Montreal New Delhi San Juan Singapore Sydney Tokyo Toronto FM_Scharff_CMS 6x9 9/21/00 2:04 PM Page ii Library of Congress Cataloging-in-Publication Data Scharff, Robert. Roofing handbook / Robert Scharff, Terry Kennedy.—2nd ed. p. cm. ISBN 0-07-136058-1 1. Roofing. I. Kennedy, Terry. II. Title. TH2431.S28 2000 695—dc21 00-062522 McGraw-Hill Copyright © 2001, 1996 by The McGraw-Hill Companies, Inc. All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. 1234567890 DOC/DOC 06543210 P/N 137056-0 PART OF ISBN 0-07-136058-1 The sponsoring editor for this book was Zoe G. Foundotos, the editing supervisor was Stephen M. Smith, and the production supervisor was Sherri Souffrance. It was set in Melior following the modified CMS 6x9 design by Joanne Morbit and Michele Pridmore of McGraw- Hill’s Hightstown, N.J., Professional Book Group composition unit. Printed and bound by R. R. Donnelley & Sons Company. This book is printed on recycled, acid-free paper containing a minimum of 50% recycled, de-inked fiber. McGraw-Hill books are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs. For more information, please write to the Director of Special Sales, Professional Publishing, McGraw-Hill, Two Penn Plaza, New York, NY 10121-2298. Or contact your local bookstore. Information contained in this work has been obtained by The McGraw-Hill Companies, Inc. (“McGraw-Hill”) from sources believed to be reliable. However, neither McGraw-Hill nor its authors guarantee the accuracy or completeness of any information published herein and neither McGraw-Hill nor its authors shall be responsible for any errors, omis- sions, or damages arising out of use of this information. This work is published with the understanding that McGraw-Hill and its authors are supplying information but are not attempting to render professional services. If such services are required, the assistance of an appropriate professional should be sought. FM_Scharff_CMS 6x9 9/21/00 2:04 PM Page ix ACKNOWLEDGMENTS his work is dedicated to Mr. Robert Scharff. His fine, clear writing Tstyle and mastery of the material are the foundation of the book. Many thanks to Michelle Martineau for her constant help and diligent approach, to Zoe Foundotos for her patience with endless questions and her ability to stay warm and human while being the consummate professional, to Stephen Smith for his grounded and steady hand in the production of this book, and to Emily Rose Kennedy for continual inspiration. Terry Kennedy ix FM_Scharff_CMS 6x9 9/21/00 2:04 PM Page x ABOUT THE AUTHORS Robert Scharff (deceased) was well-known as the author of more than 300 how-to books. He served as a consultant to industry manufacturers and contributed many articles to leading how-to and trade publications. Terry Kennedy has been a part of the AEC (architecture, engineering, contracting) business for 35 years. He has spent many hours in the field as well as in the office, working with computers since the 1980s. He is currently involved in the settlement of complex construction defect lawsuits, and that work has given him an in-depth knowledge of roofing. Mr. Kennedy has a great deal of respect for the roofing industry and wishes to thank the readers, one and all. FM_Scharff_CMS 6x9 9/21/00 2:04 PM Page xi INTRODUCTION his book was originally written for roofing contractors and crews Tinvolved with residential and commercial projects. It has been rewritten to make it an even more valuable companion to the roofing professional’s workday. Its purpose is to serve as a reference for both people with broad experience and those who are learning about roof- ing construction and maintenance. The new companion CD offers live versions of checklists and the resources presented in App. A for imme- diate use. The information in the Roofing Handbook is suitable for anyone who is involved with roofs in any way: architects, general contractors, building owners, insurance professionals, experts, and equipment manufacturers. The list of people who require knowledge of roofs is long, and this book is a handy reference for any of them. It has a clear, easy-to-understand format and contains step-by-step construction procedures as well as up-to-date product information and techniques. It also takes the reader through the business of roof- ing, estimating, and the steps to take to win a contract and launch a job. The techniques related to different types of roofs are covered on a chapter-by-chapter basis, and equipment purchases and safety concerns are also reviewed. Measures that can protect a business, such as warranties, and con- tract information to help the roofing contractor maintain a profitable bottom line, including suggestions for new business that is both innov- ative and complementary to the roofer’s present work, are also explored. Chapter 1 provides a general overview of the roofing industry, including life expectancy and a review of the various types of roofs. xi FM_Scharff_CMS 6x9 9/21/00 2:04 PM Page xii xii INTRODUCTION How do you plan for and bid on a roofing job? Do you know your actual cost of doing business? Are you making a profit? How do you coordinate your time on the roof with the other trades? What does customer satisfaction involve? These transitional parts—moving the beginning parts of a job from the office into the field—are covered in Chap. 2, “Planning a Job.” Safety is such an important part of roofing that we dedicate all of Chap. 3 to the subject. From Occupational Safety and Health Admin- istration (OSHA) guidelines to ordinary common-sense decisions, this chapter looks at how to prevent injury. The Roofing Handbook even provides a safety plan that is important for a company’s workers, increases everyone’s sense of well-being, and can actually have a seri- ous effect on bottom-line profits. The safety plan, along with many other lists, is available on the enclosed CD for printing and using as a part of doing business. Roofing equipment, from hand tools to heavy lifting machinery, is described in Chap. 4. In Chap. 12, the business chapter, the subject of major investments is discussed as a part of the general course of grow- ing a business. In Chap. 4, the subject is examined specifically in rela- tion to how an owner evaluates purchases of expensive equipment. Will the payoff from the purchase be timely for the health of the com- pany or put too much of a crimp in the flow of cash? Chapter 5 details the techniques of working with built-up roofing. This popular roofing method can be applied successfully to a variety of substrates, and the information in this chapter tells how. Lightweight and easy to install, single-ply roofing is a popular choice among building owners and roofing contractors. Chapter 6 looks at the available materials and the appropriate installation methods. Asphalt roofing comes in a variety of forms and can be applied in pleasing designs to new roofs or over existing roofs that have been pre- pared properly. Chapter 7 details installation methods, as well as roof- ing accessories such as flashings, gutters, and downspouts. Chapter 8 covers the special installation techniques required for wooden shingles and shakes. They can now be made fire- and wind- resistant if they are manufactured well and application procedures are followed professionally. FM_Scharff_CMS 6x9 9/21/00 2:04 PM Page xiii INTRODUCTION xiii Chapter 9 provides valuable information concerning the installa- tion of slate roofing materials, including repair procedures for existing roofs. With a life expectancy of 75 to 100 years, slate is a fine and stately option for high-quality jobs. Chapter 10 follows up with an in- depth guide to clay and concrete tiles. As everyone involved with roof- ing knows, concrete tile roofs have spread from Europe to the United States and become more important every year. Metal roofing, from thin copper to corrugated sheet metal, has been a popular roofing material for many years. Chapter 11 looks at the many benefits offered by metal roofs in both new and reroofing applications. Chapter 12 guides the roofer through a breakdown of the business of roofing. These basic principles were also noted in other chapters when the material came up. Chapter 13 takes the information reviewed in Chap. 12 and digs into what computers can actually do to enhance efficiency on a nuts-and-bolts basis. The intelligent use of computers is a must in order to be successful at business in the twenty- first century. Chapter 14 offers the reader a look at some types of work that can augment the cash flow of your roofing business. It also offers a glimpse of the expanding future of the roofing industry. The twenty-first cen- tury is ripe with changes and opportunity. Roofing material manufac- turers are now marketing their own roof drains and supporting specifications that make roofers responsible for the installation of these features. Nondestructive testing methods are available to roofers as a means of assessing existing roofs for moisture content.