As the single-largest capital improvement project in the history of San Antonio, Texas, the SAIA Terminal Expansion is a significant investment expected to serve the community for decades. Not only did the completion of the $200 million expansion pose unique design challenges and construction risks, it was also completed in the midst of a fully operational airport.
To meet the twenty year, seventy mph wind, durability and energy efficiency requirements of the roofing system, the architects selected Sika Sarnafil’s reflective 72mil PVC G410 Membrane fully adhered with Sarnacol 2121 water-based adhesive to mechanically attached 25” DensDeck Prime over 25psi Sarnatherm Polyisocyanurate board, most of which was tapered. The roof was installed over a variety of substrates including steel and concrete, sloped and level at 14 different decks at a variety of elevations.
Texas Fifth Wall Roofing Systems also provided skylight installation, tenant work for concessionaires, curved metal roof panels, and cantilevered translucent panels at the terminal’s passenger drop-off area.
The Installation Process
Fifth Wall joined forces with Clark/Byrne and Sika Sarnafil to ensure installation of the roofing system progressed as planned.
Due to site’s controlled access and international airport security, a higher than normal level of coordination for material delivery and staging was required. Fifth Wall worked closely with Sika Sarnafil to coordinate material deliveries and with Clark/Byrne field superintendents to make sure efficient staging of materials with minimal disruption to other trades.
As expected of large-scale projects like SAIA, the opportunity for design or application issues to cause delays or rework is significant. On one occasion, the tie-in to the existing adjacent terminal presented a unique set of problematic conditions. Onsite consultation was instrumental in developing detailed solutions incorporating Sarnaclad coated metal that maintained the integrity of the building shell and met the requirements of the Sika Sarnafil warranty.
On another occasion, a significant defect in a prefabricated steel column caused an unanticipated bulge in the sloped deck. Fifth Wall utilized its combined knowledge of local building and fire codes and the manufacturer’s requirements to evaluate alternatives and make a recommendation that minimized the cost of rework.
Combined with Sika Sarnafil’s responsiveness and ability to quickly provide additional materials, the matter was resolved at a minimal cost without schedule delays.
Clark/Byrne, Sika Sarnafil and Fifth Wall worked as a committed team on a project spanning three years and eighteen months of roofing work, and were able to successfully meet the original completion date in spite of a myriad of obstacles.