The five-person team from Statewide Roofing left our job site at 4:30 pm, after completing the white membrane on the upper-, mid- and lower flat roofs. 

Manny, from MWB Pools, arrived on site today and worked with Izzy, the master trencher, on installing the 6-inch pipe that will take our overflow water when our underground cistern is full, to the storm drain on Winchester Boulevard.

The only problem was that the inspector, Steve Souza, from the Town of Los Gatos wasn’t available to inspect the connection to the back of the storm drain.  Steve will inspect our connection between 9:00 am and 12:00 noon tomorrow.  When we pass this inspection, we can backfill the open trench on Winchester.

Completing Our ‘Cool Roof’

The five-person team from Statewide Roofing are impressive.  First, they know exactly what they are doing and can move quickly and efficiently.  Second, they are always smiling and having fun together.  That really helps with a team spirit, and is somewhat infectious.  Finally, you can see that they all take pride in their work and are always focused on doing a good job.

Installing the 6-Inch Drains to Winchester Boulevard

One of the last components of our water catchment system is to provide the overflow from our 3,677 gallon underground cistern to the storm drain on Winchester Boulevard.  This overflow is to be a 6-inch pipe, going from the cistern to the storm drain.

On Friday, Izzy dug the trench to the storm drain and today Manny and Izzy put the pipe in.  To do so, they have to make a hole in the concrete into the back of the storm drain, which they did. 

The Town of Los Gatos asked us to drill holes in the back of the storm drain and epoxy #3 reinforcing steel (rebar) into the holes.  Then, we will pour concrete into the connection such that the 6-inch pipe is encased in concrete going into the storm drain.  No problem.

We were ready for an inspection before noon today, which we called.  It took until the end of the day before we were advised that the inspection would be between 9:00 am and 12:00 noon tomorrow (Tuesday).

We’re ready …

Hole through the concrete storm drain on Winchester Boulevard. Note the holes drilled around the large hole, which we will epoxy #3 reinforcing steel (rebar) into these holes.

The #3 rebar is epoxied into the concrete and the 6-inch pipe in place.

Waiting for the inspector from the Town of Los Gatos to review our work so we can pour concrete ...

Statewide Roofing sent one of their trucks to our job site to retrieve all of the unused materials. Any scraps left over will either be used elsewhere or recycled.

One of the two pipe sleeves that we ordered from BTL Liners, which will go over the 6-inch inlet and outlet pipes for our underground cistern.

Having completed the installation of our the membrane over the flat roofs, the team from Statewide Roofing leaves our job site.

Completed flat roof on the West side of the house.

Completed flat roofs on North side of house.

Completed flat roof over garage. Note how the roof is sloped to the drain on the East (left) side of the garage.

Completed mid level flat roofs around the Atrium.

Completed flat roofs at front of house, looking East.

Completed upper flat roof. Note the pipe on the North side, which can be used in the future for a satellite dish.

View of completed 'cones' for solar photovoltaic panels on upper flat roof.

Bryan picked up 10 bags of concrete mix and 1 bag of mortar mix for the drain system to the storm sewer on Winchester Boulevard.

The open trench on Winchester Boulevard is, once again, buttoned up safely and securely.

The Don and Toni team put a sign up in front of our house on Winchester. We support both Don Perry and Toni Yamamoto as election candidates in the City of Monte Sereno.

It was a good day … Nik hit a home run in his baseball game, Kate celebrated her 7th birthday with 15 friends, and it didn’t rain at our project site.

Way cool!

Happy 7th Birthday Kate!

Jo-Anne serving Birthday Kate!

The first task of the day was to button up our project site and prepare for the rain that is forecasted for tomomrrow (Sunday). 

Then, Bryan was scheduled to attend an EVent in Los Gatos that Mike Calise was hosting to raise awareness of electric vehicle charging stations that could become part of the Los Gatos General Plan.

Preparing for Rain

In general, the site was looking good and there is a 30% chance of rain in the forecast.  Yesterday, the team from Statewide Roofing completed the ‘bottom layer’ of membrane on all of the flat roof sections.  In addition, they put in the 13 downspouts through the SIP roofs, which were provided by Wildcat Metals.  There were a couple seams where the transition from the gable roof to membrane could gather water.  And the skylights were not in.

Bryan made a quick trip to the Home Depot and bought a roll of Tyvek tape.  With the tape, he ensured the transition on the gable roofs to the membrane was seamless (so to speak).  And he covered up the four skylights with extra membrane so the rain will not enter the house.

We’re ready for the showers tomorrow.

Attending an EVent in Los Gatos

Mike Calise, an independent cleantech advisor for EVadvise (mike@EVadvise.com) is involved with electric vehicles (EVs) and their associated infrastructure.  One of the major barriers to the widespread adoption of all-electric vehicles is the short battery life, which limits the range of EVs between charges.  And, it takes time to charge an EV (unlike filling up a tank of gas quickly).

On July 31, 2010, we put down a deposit on a Nissan LEAF, so we are very interesting in seeing EV charging stations everywhere.  We enjoy being ‘early adopters’ of technology and new products.

Currently, the Town of Los Gatos is completing their 2020 General Plan and Section 9 Environment and Sustainability Element includes actions on providing and supporting EV charging stations and preferred parking for EVs. 

Mike and Donna Calise hosted an informational session at their home on Edelen Avenue in Los Gatos where they had Mike DiNucci of Coulomb Technologies educate the attendees regarding the projected adoption of EVs and the associated infrastructure that will be required.  Coulomb Technologies offers the ChargePoint family of products, which provide an easy to use, comprehensive platform for utilities, municipalities and corporations to deliver EV charging.

A number of interested residents attended the EVent.  There were several members from the West Valley Green Leaf Committee there, as well as Ira Spector (husband of the former mayor of Los Gatos, Barbara Spector) and current Town Council Candidate, Steven Leonardis.

The objective of the meeting was to share knowledge regarding EVs and the associated infrastructure in order to provide additional input to the Town Council at their meeting on Monday, September 20.  Currently, the language in the 2020 General Plan regarding EV charging stations is somewhat weak and Los Gatos has an opportunity to strengthen the language and establish a mandate to support the adoption of EVs.  Each person attending the meeting will be allotted three minutes to speak in the council chambers. 

We believe that, by providing EV charging stations in Los Gatos, the town could become a destination for EVs and their associated spending in local businesses. ’Range anxiety’ limits EVs to local travel and known charging stations.  The demographics and purchasing power of individuals that will own EVs is very attractive to the businesses located in Los Gatos, so providing EV charging stations and preferred parking could bring those individuals to Los Gatos and benefit our local businesses.

This message needs to be communicated to Los Gatos Town Council so they can strengthen the wording in the 2020 General Plan.

We will be including two 50 amp 240 volt circuits in our garage so we can charge two electric vehicles simultaneously. 

Mike and Donna Calise hosted an EVent in their back yard on Edelen Avenue in Los Gatos.

Mike DiNucci providing an overview of electric vehicle adoption in the U.S. and associated infrastructure requirements.

Mike Calise, left, taking notes to prepare for the Los Gatos Town Council meeting.

We were extremely focused on completing the installation of the single ply membrane over our flat roofs today, as the weather forecast for Sunday continues to include a 30% chance of rain.

Also, Izzy completed the trench under the sidewalk and to the Verizon (formerly GTE) underground vault on Winchester Boulevard.

Trenching to Winchester

With our Comprehensive Trenching Plan, we are harvesting 100% of the rainfall from our roof and storing it in our underground CUDO cistern.  When the cistern is full, any additional water flows directly into the back of the storm drain on Winchester Boulevard. 

Although the 4-inch perimeter drainage system is in place, it must still be connected to the underground CUDO cistern.  Yesterday, we ordered two ‘boots’ to connect the 6-inch inlet pipe and 6-inch outlet pipes to the cistern.  We ordered this boots from BTL Liners, and they were delivered today.

Our master trencher, Izzy, dug a trench to the storm drain on Winchester Boulevard.  He dug another trench to Verizon’s underground vault, 11 ft away.  We put a 2-inch conduit into this trench and backfilled it.  This conduit will go underground to our East Mechanical room, so we can have a future connection for telephone services.  We’re hoping that, some day, we will have a fiber optic connection in this conduit.

Continuing to Install Our ‘Cool Roof’ System

The five-person team from Statewide Roofing completed the basic installation of the single ply membrane over all of our flat roofs today.  They will be back on Monday to complete the detailing and to test all of the seams.

During the day, Bryan spoke with Mandy Schwietzer a Technical Services Specialist for TPO single ply membranes with Johns Manville in Littleton, Colorado regarding some issues that our Building Official, Howard Bell, had raised.  Howard was concerned with the placement of the screws holding down the tapered insulation.  He had inspected a project on Overlook Road where the tapered insulation had curled after being installed and he didn’t want that to happen with our project.

Mandy provided technical documentation and confirmed that the multiple screws holding down our membrane will ensure the tapered foam insulation will remain flat and that the membrane will be secured to the SIPs and come apart.

Statewide Roofing had a comprehensive installation guide for the complete line of single ply membrane products from Johns Manville available on our project site.

Howard approved our installation and documented his approval on our building permit.

At the end of the working day, Bryan ensured the gate was locked and all the safety signs were in place before leaving the project site.

Installing the tapered insulation over the garage, at the front of the house.

Ready to put the membrane over the tapered insulation at the front of the house. Note the small crickets in the flat part in the center of the roof.

Using a stretcher to ensure the single ply membrane is straight on the East side of the garage.

Welding an outside corner with a hot air welder around one of the skylights on the West side of the house.

The welding must be done perfectly so the membrane will be completely watertight.

Trench going to the back of the storm drain on Winchester Boulevard. We will drill through the back of the storm drain and connect our underground CUDO cistern directly to the storm drain with a 6-inch pipe.

Izzy dug a narrow trench to the Verizon (formerly GTE) underground vault and put in 2-inch conduit. This conduit will be terminate in the East Mechanical room and may, some day, have fiber optic cable in it.

The trench to the green Verizon underground vault (left side) is backfilled and compacted, and the open trench to the storm drain is covered and the sidewalk blocked safely.

The crew from Statewide Rentals clears their remaining items on the roof so we're prepared for the rain. Currently, it doesn't look like it will rain ...

Buttoned up securely for the weekend.

The five-person team from Statewide Roofing returned today to continue installing our tapered insulation and white membrane over our flat roofs.  The weather forecast for Sunday continues to include a 30% chance of rain.  We’re focused.

We had to change the ‘About‘ page on our web site.  Kate is now 7 years old (her party is on Sunday afternoon, which increases the probability of precipitation dramatically).

Tapered insulation over the mid level flat roof on the North side of the house, held in place with at least four (4) screws.

Tapered insulation on the East side of the house, covered with FR-10 slip sheet.

Tapered insulation under the Dining Room gable roof, where there is a step up to the mid-level flat root.

One of the 48 mounts for our solar photovoltaic system. There are three screws holding the single ply membrane in place. This penetration must be completely waterproof.

An 18 inch square piece of membrane is welded over the penetration, making a base that can be welded onto.

Making a 'cone' with a flat base that can be welded onto the base.

A roof of cones, ready to mount the frames to hold our solar photovoltaic panels.

Low VOC adhesive for attaching the membrane to the gable roof.

Using an automated hot air welding machine to weld the seams on the lower flat roof.

Our daughter, Kate, blowing out the candles on her 7th birthday cake (a chocolate Bundt Kate!).

The team from Statewide Roofing arrived promptly at 8:00 am this morning to install our cool roof system.   We need to get the flat roof completed before the rains come this weekend.  Depending on which forecast one follows, there is a 10% to 40% chance of rain on Saturday and/or Sunday.

We need a roof.  And a ‘cool roof’ would be way cool.

Designing Our ‘Cool Roof’

Our roof serves multiple purposes.  First, it provides us with shelter (go figure).  Beyond this basic function, we have the following requirements:

• Reduce our heating and cooling requirements.
• Allow us to capture 100% of the rainwater from the entire roof.
• Reduce our maintenance requirements.
• Support our solar photovoltaic panels.

The benefits that we will enjoy from our roof design include:

• Reduced energy costs, due to reduced energy consumption and the generation of electricity.
• Reduced maintenance costs, due to lower maintenance requirements and faster and easier maintenance activitivies.
• Increased occupant comfort, due to higher temperatures in the winter and cooler temperatures in the summer.

Roof Surfaces and Defining a ‘Cool Roof’

According to Johns Manville’s handbook on single ply roofing systems,

‘Roof surface temperature is important to reducing air conditioning energy usage and mitigating the Urban Heat Island Effect. Cool roof surfaces minimize heat build-up in the roof membrane caused by solar radiation (the sun) and the transfer of heat from the hot roof into the building. The roof is one of the first lines of defense against the effects of the sun on and in a building. In addition, roof insulation plays a critical role in reducing the heat flow into the building. With proper insulation and the addition of cool roofing products, heat transfer into a building can be reduced significantly.

A cool roof surface is defined by two mechanisms, reflectivity and emissivity. The higher the reflection of the total solar energy spectrum (called the albedo), the less solar energy is absorbed. The second mechanism, emissivity, is the amount of absorbed heat that is re-radiated back into the atmosphere. Thermal emissivity is expressed as a percentage relative to an ideal radiating surface, which is defined as having an emissivity of 100%. Thus, when less energy is absorbed (high solar reflectivity) and more of the absorbed energy is emitted (high thermal emissivity), there is less thermal energy (e.g., heat) in the roof to enter the building. For example, metals have low emissivity, and that is the reason why a highly reflective piece of metal left in the sun still becomes hot compared to a highly reflective, more emissive roof membrane. Reflectance and emittance with proper insulation are critical properties to a properly functioning cool roof.’

What could be cooler than a ‘cool roof’? 

Eliminating Water from Ponding on Our Roof

Starting with shelter, we don’t want the roof to leak.  On our 12:12 pitch gable roofs, this will not be a problem.  However, on our flat roofs (upper-, mid- and lower flat roofs), we may experience ‘ponding’.  Allan Courtney, our roofing advisor and roofing contractor, recommended that we design the flat roofs to direct water to the drains.  Note that all of the water from our gable roofs, and upper- and mid level flat roofs goes onto our lower flat roof.  This can be a lot of water.  Al doesn’t want there to be any ‘flat’ areas on our roof for water to pond.  Ponded water is bad, as it can be a source of water that could then leaks into our house.  We would very much prefer that 100.0% of the water from our roof go into our underground cistern.

In addition, ponded water is heavy, which increases the load on the structure.  Increasing the load can cause the roof to deflect, causing more ponding.  More ponding can cause more deflection …

So, Al recommended that we have tapered foam crickets from Johns Manville.  Each of the tapered foam crickets are manufactured in 4 ft x 4 ft pieces from closed cell polyisocyanurate foam. 

ENRGY 3® and ISO 3™ are rigid roof insulation boards composed of a closed cell polyisocyanurate foam core bonded in the manufacturing process to universal fiber glass reinforced facers. ENRGY 3 and ISO 3 utilize an environmentally compliant blowing agent containing pentane hydrocarbon to enhance the thermal performance of the foam insulation. This hydrocarbon has zero ozone depletion potential and conforms to the Montreal Protocol established in 1987. ENRGY 3 and ISO 3 meet the physical property requirements of ASTM C 1289, Type II, Class I, Grade 2 and CAN/ULC S704, Type 2, Class 2. ENRGY 3 and ISO 3 specialty products are also available as tapered panels, precut miters and precut crickets.

To direct the water to the drains, the crickets need to be engineered so that, in every instance, there is a downward slope that leads to a drain.  Johns Manville provided us with this design service as it is included in the cost of their product.  Here is the design of our tapered insulation, which Leo Richardson drafted.

Although we don’t need to have additional R-value for our roof, installing tapered insulation as crickets will eliminate the structural thermal bridges on our flat roofs. 

Reducing Energy Consumption

Our roof design started with reducing our energy consumption, which is one of the reasons for using SIPs (structural insulated panels).  Our SIP roof provides thermal resistance of R-47.  This high thermal resistance does not prevent solar radiation from reaching the inside of the house and heating the house.  To reduce energy consumption for cooling the house, we need to reflect that heat back into the sky.  Reflecting solar radiation can be accomplished with a roof surface with high solar reflectance and high thermal emittance.  This is the value of a light colored (e.g., white) roof.

The R-47 thermal resistance does not include the structural elements inside the SIPs that create thermal bridges.  For example, we have a 5.25×16 SCL (structural composite lumber) in the center of our upper flat roof that is not insulated.  Without the tapered insulation, we would have thermal bridges where heat (energy) can escape, or enter, our house.  The tapered insulation will reduce the thermal bridges as it will add, on average, R-7.5 to our thermal envelope on our flat roofs.

Components of Our Roofing System

In evaluating the roof surface over the SIPs, Al recommended a white, 60 mil TPO Membrane from Johns Manville.  This product has an extremely high initial solar reflectance of 0.77 and an extremely high initial thermal emittance of 87%.  To put these values into context, meeting the EPA’s Energy Star standards requires a solar reflectance of 0.65 and meeting the higher standards of California’s Title 24 requirements for commercial buildings requires solar reflectance of 0.70 and thermal emittance of 75%.

Al recommended TPO Membrane as it is manufactured from thermoplastic polyolefin (TPO).  Single ply roof membranes are manufactured using EPDM, PVC or TPO.  Al prefers TPO because it is easier to keep clean, which lowers our maintance requirements and, consequently, maintenance costs.  Dirt will lower the solar reflectance and lower the thermal emittance.

JM TPO is one of the latest single ply, flat roofing materials on the market. The current membrane formulations are reinforced with a polyester fabric and manufactured using an ultraviolet-resistant thermoplastic polyolefin formulation. TPO from JM comes in several thicknesses. It is designed for use in mechanically fastened and adhered roofing applications in new, re-roof and re-cover roof constructions. It is fire and chemical resistant and contains UV inhibitors for added longevity.

Products with a longer useful and functional life contribute to the durability of the building envelope, which can result in a lower overall total cost of ownership for our house.

Regarding the attachment system, Al recommended that we go with mechanical fasteners.  The alternative is a fully adhered roof membrane.  Given his experience, Al recommended that we use Carlisle’s HP-x fasteners with 3 inch plates for the tapered insulation and 2-3/8 inch Piranha plates to mechanically fasten the membrane.

Over the tapered foam insulation and under the single ply membrane, Al recommended FR-10 slip sheet.  The slip sheet serves two purposes – allows the membrane to move as it expands and contracts with heat and cold, and adds protection against flame spread and flame penetration through the roof system.

Roof installation instructions.

Installing Our Cool Roof

The six-person team from Statewide Roofing brought a portable diesel generator on our site and moved their tools onto the roof.  Then, the roofing materials arrived from Ford Wholesale, and they were placed on our roof with a rear pivot steer Telehandler.

The team got to work quickly, cleaning the debris from the roof and distributing the 4×4 sections of tapered insulation.  Then, they attached the insulation with screws to the SIPs and put down the slip sheets.  The membrane went down next, fastened with the screws and Piranha plates.

Then, the detail work started, which is welding the seams of the membrane.  it was a sunny, hot day, and the new white membrane reflected the solar heat, making it even hotter for the team working on the roof.

All of the tapered foam insulation that was secured to the roof was covered before the team left for the day.

Way cool …

Ready for the materials to arrive and be lifted onto the roof.

The Telehandler unloads our roofing materials on Via Sereno.

Placing the materials on the roof.

Our neighbor from Vista Avenue, Robin Wedell, was walking her dog around the block and stopped in for a visit. Justin Barlett, on the left, was working on pressurizing our geothermal ground loop.

Roofing the lower flat roof on the West side of the house. Note the FR-10 slip sheet and the fasteners holding down the white single ply membrane.

Completing the detailed work on the upper flat roof. The seams are welded with a special hand held hot air welding tool.

4x4 sheets of ENRGY 3 tapered foam insulation from Johns Manville.

A bucket of 2-3/8 inch Pirahna plates.

Roll of FR-10 slip sheet material, which allows the membrane to expand and contract, and provides protection from the spread of fire through our roof assembly.

Fasteners for the insulation and roof membrane.