Washington BUR

Multi-Year Project Completed: 390,000 sq.ft. Reroof of Packaging Facility

by Jeff Denenholz, Thomas Center


From Western Roofing Jul/Aug ’12


Alliance Packaging, with headquarters in Washington State, is the Northwest’s largest independent corrugated box manufacturer with a well-deserved reputation for producing the very best in packaging products. They also operate facilities located in Oregon, Idaho, and California, and sell their products throughout the United States and Western Canada.

Alliance provides packaging solutions ranging from custom shipping containers to retail packaging, from stock boxes to in-store displays, from creative design to same day delivery service. The company has invested in resources to handle all aspects of their customers packaging needs and features a highly capable team, the industry’s most modern information technology, a full complement of state-of-the-art converting equipment, and industry-leading operating practices.

The company bought a warehouse facility in Washington State in 1999 and completed an addition for administrative offices in 2001. Alliance managers in charge of facilities had a huge challenge on their hands to not only keep the original roof installed in the late 70’s functioning but also to plan for a complete reroof project consisting of 390,000 square feet.

Alliance relied on their long-term relationship with Edifice Construction Company, Woodinville, Wash., to recruit a competent roofing contractor that specializes in large commercial roofing projects. Edifice turned to their long time vendor Stanley Roofing, also located in Woodinville, Wash. Consulting with Edifice, Stanley, and other roofing consultants, Alliance continued to research a wide range of roofing options in an effort to determine which was most cost-beneficial for the company. In the meantime, Stanley diligently worked to patch numerous leaks throughout the old facility. Around 2008, Alliance and Stanley agreed to a design and multi-year reroofing project to be completed in sections.

The project began in 2009 and was completed this year with the last 150,000-square-foot section. All of the parties learned some valuable lessons. The Alliance management was able to better prepare and approve yearly budgets for the project by requesting and receiving scope-of-work proposals at least six months in advance.

Malarkey Roofing Products, System-M4-XlH and M4-X|B was used in areas of ponding water at the perimeter edges. This system was installed over DensDeck® primed. Malarkey provided a No Maximum Limit 20 year Warranty without limitations on ponding water. The built-up roof flashings consisted of #501 SBS base sheet and one layer of #601 SBS White Mineral Surface Cap Sheet. The sheet metal copings and counter flashings were custom fabricated from AEP Span 24-gauge Kynar® pre-finished flat stock in the Stanley sheet metal shop. The supplier for the project was Pioneer Builders Supply Co., Tacoma, WashINGTON.

Relationships matter a lot. The relationship between Alliance and Edifice spans more than 30 years. Likewise, the relationship between Edifice and Stanley spans more than two decades. Alliance trusted Edifice to select the roofing contractor able to complete the huge project. Edifice turned to their roofing specialists. Whenever working with a combination of new and old surfaces, there is no such thing as a perfect roof. Leaks are likely to occur in the transition areas. It’s important to prepare with the equipment and resources to quickly complete the patches to enable the clients to continue to operate.

Stanley Roofing is a leading provider of roofing systems to the region’s premier companies such as Bartell Drugs, Ivar’s Restaurants, Franz/Gai’s Bakeries, Alliance Packaging, and Steadfast Development, owners of the Everett Mall. Since 1954, this family owned and operated business has specialized in commercial roofing projects, maintaining the highest quality and most affordable costs. Stanley Roofing has the experience, equipment, manpower, and insurance to handle the toughest projects.

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