Projects 2018-01-02T15:40:34+00:00

PAVER AND STRUT KNUCKLEHEADS UPGRADE COOLING SYSTEM SUPPORT DURING RE-REROOFING

This project involved the installation of KnuckleHeads to improve the support structure of a rooftop cooling system during a commercial re-roofing job.

The building was an approximately 28,000-square-foot facility housing a large internet service provider located in Southfield, Michigan. The cooling system included three large chillers and associated pipes and conduit that were originally supported in some areas with wood sleepers sitting on top of

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BEFORE Chiller feet cantilevered on steel curbs

CoolingSystem-WoodSleepers

BEFORE Pipes on rotting wood sleepers

polypropylene bases and in other areas with galvanized steel curbs. In places, the chiller feet were cantilevered on the steel curbs. EPDM membrane was used to replace the original coal tar roof. The chillers and piping were gently lifted during tear-off and membrane installation, then reset using two types of GreenLink KnuckleHeads. To support the chiller feet, paver KnuckleHeads were selected. But because chillers are sensitive to leveling—fans operating in units that are not level will burn out their bearings more quickly—the paver supports were modified. The standard paver 7” head was expanded to 12” to comfortably accommodate the full footprint of the chillers, eliminating any cantilevering. Chem Link M-1® adhesive/sealant was used to bond KnuckleHeads to polyester risers, which were loose laid onto EPDM slip sheets. Because KnuckleHeads are height adjustable, a level, evenly distributed load was achieved. In addition to the modified paver KnuckleHeads, strut KnuckleHeads were installed to support Unistrut steel channel for elevating piping and conduit. The reinstallation of the cooling system was completed in a day.

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AFTER Chiller supported on custom 12” Paver KnuckleHeads

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AFTER Wood sleepers replaced with Strut KnuckleHeads supporting

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AFTER Two types of KnuckleHeads handle the job

REPLACING WOOD SLEEPERS ON LOW-SLOPE ROOF

This low-slope TPO roof on a public-school building in Michigan shows the flaws of using wood sleepers and the advantages of Solar / HVAC KnuckleHeads for pipe supports.

Loose-laid sleepers are subject to movement, over time causing pipes to bend and contort. In addition, the wood will deteriorate and rot from weathering and biological attack. In some cases, the rotting wood allows screws to loosen causing brackets to detach so that they can no longer hold pipes in place. This project involved replacing the sleepers with three types of KnuckleHeads. Heavy Pipe KnuckleHeads were used to support gas lines (black pipes). Strut Supports and Lite Pipe Supports were used for electrical conduit (light grey pipes), which powered multiple HVAC systems. Dual conduit lines were supported by aluminum channel set in Strut Supports while Lite Pipe Supports were used for elevating single lines.

WoodSleepers

BEFORE: Electrical conduit and gas pipe supported on deteriorating wood sleepers

BEFORE: The wood will deteriorate and rot from weathering and biological attack

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AFTER: Conduit placed on aging sleepers replaced with aluminium channel supported by strut KnuckleHeads

AFTER Conduit placed on aging sleepers replaced with aluminum channel supported by strut KnuckleHeads

AFTER Heavy Pipe Supports elevate gaslines

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AFTER M-1 adhesive is used to bond KnuckleHead base to roof substrate

                   

AFTER: Completing the job

AFTER Lite Pipe KnuckleHead supports single conduit pipeline

PREVENTING LEAKS WHEN PENETRATING THE MEMBRANE

When mechanical fasteners are used, a patch can be applied to ensure there are no leaks. First M-1® is used to bond and seal the base. Next a patch cut from the TPO membrane is placed around the KnuckleHead and heat welded in place.

This project on a California gas station involved installation of solar thermal panels over an approximately 8,000-square-foot roof covered with TPO single ply membrane. Strut KnuckleHeads and extensions supporting Unistruts were used to angle the panels at a 15 degrees.
The contractor applied 1/4-inch screws to install the KnuckleHead bases. To prevent possible leaks caused by penetrating the membrane, the contractor first used M-1 to seal around the base, followed by the “patch method.” Round sections, or “targets,” cut from TPO membrane were placed over the base and heat sealed around the edges to prevent possible leaks. The installation was approved by the building inspector.

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18” extensions elevate strut supports to achieve 15 degree panel

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M-1 bonds base to membrane and also seals roof screw heads

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FINISHED INSTALLATION target flashing heat welded in place

REPLACING WOOD BLOCKS WITH THE KNUCKLEHEAD ROOFTOP SUPPORT SYSTEM

This project involved replacing wood blocks with KnuckleHead supports as part of roof upgrade on a retail building in East Lansing, Michigan.  The contractor had applied a two-coat liquid polyurethane coating over an aging BUR.  Installers had to work around dozens of deteriorating wood blocks which had been used to support multiple steel gas lines and some electrical conduit coming from HVAC units.

Following the completion of the topcoat, Green Link personnel handled the removal of the blocks and the installation of the KnuckleHeads.  Three types of KnuckleHeads were utilized:  Heavy Pipe supports for 2½-inch nominal pipe size steel gas line pipes, Lite Pipe KnuckleHeads for smaller lines ranging from ¾” to 1 ½” diameters, and Strut KnuckleHeads for steel channel which supported pipeline clusters.  The Knuckle Head designs contributed to an easy and efficient replacement strategy.  KnuckleHeads were placed under the pipes and conduits adjacent to the wooden blocks.  Because KnuckleHeads can be elevated by turning the heads clockwise, this allowed the pipes to be raised above the wood blocks so they could be removed.  The wood supports had to be cut out with a razor edge because the coating had been applied from the roof surface up along the sides of some of the blocks. Once the blocks were removed, the contractor was able to apply liquid urethane to the uncoated areas.  The loose laid KnuckleHeads were then lowered to the desired height and spaced to provide optimum load distribution.  Each KnuckleHead was placed on a GREEN LINK KnucklePad, a yellow-tinted urethane pad to protect the roof coating.  The project involved approximately 100 KnuckleHeads:  40 were utilized to support steel channel ranging from two feet to six feet in lengths; 30 large pipe supports and 30 lite pipe supports completed the job.

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