Projects2018-10-12T18:12:00+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 GREEN LINK 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. GREEN LINK 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 re-installation 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

CUSTOM ENGINEERING OF KNUCKLEHEADS

This project involved a combination of standard KnuckleHead Lite Pipe, Heavy Pipe and Strut Supports along with GREEN LINK custom-molded products that were engineered to fit the specific demands of the roof structure.

An airplane maintenance facility located in southwestern Michigan required replacement of its rooftop pipe system, which utilized wood sleepers of varying sizes. 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.  A section of the steel corrugated roof presented an unusual challenge.

Specially designed polyurethane saddles were custom molded by GREEN LINK to fit on top of the corrugated contours of the roof.  One design accommodated steel strut for supporting multiple large pipes in a perpendicular configuration, while another design accommodated the Lite Pipe KnuckleHead for supporting smaller pipes. Additionally, a section of the roof featured a standard low-slope design. Here, standard Lite Pipe and Heavy Pipe KnuckleHead Supports with extensions and KnucklePads met the requirements of the job.  Both Lite Pipe and Heavy Pipe supports were capped using KnuckleCaps and KnuckleStraps to secure pipes in place.Captions, starting upper left and moving right:

BEFORE

BEFORE

BEFORE

A Lite Pipe KnuckleHead Support rests on a GREEN LINK custom molded polyurethane saddle.

DURING THE INSTALLATION: A Lite Pipe KnuckleHead Support rests on a GREEN LINK custom molded polyurethane saddle.  Pipe is secured with a KnuckleCap.  Original wood sleepers shown at right and left.

GREEN LINK custom-molded polyurethane saddle

DURING THE INSTALLATION: GREEN LINK custom-molded polyurethane saddle on roof contour accommodates steel channel for supporting parallel pipe lines.  Original wood sleeper installation shown in background.

Lite Pipe KnuckleHead with Extension and Wooden Block Comparison

DURING THE INSTALLATION: A Lite Pipe KnuckleHead Support replaces wood sleepers for supporting 1” nominal pipeline.

Heavy Pipe KnuckleHead is supporting a larger pipe.

DURING THE INSTALLATION: Heavy Pipe KnuckleHead is supporting a larger pipe.

OVERHEAD VIEW:  Large pipe rests on steel channel bolted to a GREEN LINK custom molded polyurethane saddle.

Lite Pipe KnuckleHead rests on flat roof membrane

OVERHEAD VIEW:  A Lite Pipe KnuckleHead rests on flat roof membrane.  Installation includes non-slip KnucklePad under base and KnuckleCap to secure pipe.

FINISHED INSTALLATION

FINISHED INSTALLATION

Heavy KnuckleHead Installation

FINISHED INSTALLATION

FINISHED INSTALLATION

Heavy Pipe Installation

FINISHED INSTALLATION

KnuckleHeads Installation

FINISHED INSTALLATION

KnuckleHeads

FINISHED INSTALLATION

FINISHED INSTALLATION

KnuckleHead Installation

FINISHED INSTALLATION

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

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

BEFORE: Removing wood sleepers before the KnuckleHead installation

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

AFTER Heavy Pipe Supports elevate gaslines

                   

AFTER: Completing the job

AFTER Lite Pipe KnuckleHead supports single conduit pipeline

AFTER Lite Pipe KnuckleHead with KnuckleCap keep the pipe safely in place

AFTER Installing Heavy Pipe KnuckleHead and KnuckleStrap

PREVENTING LEAKS WHEN PENETRATING THE MEMBRANE

When mechanical fasteners are used, a patch can be applied to ensure there are no leaks. First GREEN LINK  Adhesive/Sealant 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 GREEN LINK Adhesive/Sealant 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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GREEN LINK  Adhesive/Sealant 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.

BEFORE THE INSTALLATION

FINISHED INSTALLATION

BEFORE THE INSTALLATION

FINISHED INSTALLATION

BEFORE THE INSTALLATION

FINISHED INSTALLATION

BEFORE THE INSTALLATION

FINISHED INSTALLATION

BEFORE THE INSTALLATION

FINISHED INSTALLATION

DETAILS OF THE INSTALLATION

FINISHED INSTALLATION

This project involved reroofing a retail business located in a Kalamazoo, Michigan strip mall. Pipes and equipment were originally supported by wood sleepers.  The selected bid called for putting the original wood sleepers back into place, but at the owner’s request, they were replaced with KnuckleHead Supports.

The building owner received three bids for a 6500-square foot reroof job and selected the contractor based on reputation and quality.  The winning bid called for tear-off of 1 inch of BUR roofing and perlite substrate.  The original 3” polyisocyanurate insulation was determined to be in good shape, so it was not replaced.  Mechanical attachment of ½” Dens Deck was installed according to manufacturer’s specifications. The contractor then followed with heat-welded Duro-Last® white single-ply membrane as well as 2-piece fascia with Kynar® finish.

HVAC equipment and associated pipelines were originally placed on wood sleepers.  The bid did not call for replacement of the sleepers, so following the installation of the membrane, original wood blocks, some of which had already deteriorated from weathering, were put back in place.  The building owner was familiar with the KnuckleHead product line and requested that the contractor replace the original sleepers with KnuckleHead supports.  The completed job required 4 Strut Supports, 14 Lite Pipe Supports, 18 non-slip protective KnucklePads and 14 KnuckleCaps for securing pipes.

Following completion of the project, the owner stated, “I had a nice new roof and I wanted to make sure the support system matched the quality of the roof.  The KnuckleHeads represented very little additional cost, and now I can be sure that all that stuff up on the roof is secure and safe for the long run.  The finished job looks great.”

BEFORE THE INSTALLATION

AFTER THE INSTALLATION

Wood sleepers were supporting pipelines…

 

KnuckleHeads replace wood blocks

 Deteriorated wood sleepers have been replaced with KnuckleHead Lite Pipe Supports

Wood sleepers were supporting pipelines…

 

 Deteriorated wood sleepers have been replaced with KnuckleHead Lite Pipe Supports

KnuckleHeads replace wood blocks

…and air conditioning units

 

KnuckleHeads replace wood blocks

Strut KnuckleHeads support air conditioning unit, keeping it level

 

…and air conditioning units

 

Strut KnuckleHeads support air conditioning unit, keeping it level

 

Wood blocks had deteriorated from weathering, causing metal straps to come loose

 

Molded polyurethane KnuckleCaps secure pipeline, ensuring a durable installation