In April of 2019, funding became available that would enable Penn State Behrend to invest in a dramatic upgrade to the historic Federal House in Erie, Pennsylvania. The brick building, constructed in 1838, is thought to be the oldest structure in Harborcreek Township. According to the Harborcreek Historical Society, it was originally the two-story home of a cobbler, Thomas Bonnell, his wife Eva, and their nine children. In later years it became a safe house for slaves traveling the Underground Railroad.

The goal of the renovation was to create a new home for Penn State’s Susan Hirt Hagen Center for Community Outreach, Research, and Evaluation (CORE). The project was 100 percent private- and university-funded. As an outreach center for the college’s School of Humanities and Social Sciences, CORE is dedicated to promoting positive outcomes for Erie young people by helping them navigate the challenges of adolescence and early adulthood.

The expansion, which connects the original brick building to a new, contemporary structure, will enable CORE to expand its programming, bolstering its safety net of school, family, and community resources.

The Challenge

According to Brett Younger, who supervised the roof and wall system portion of the renovation project, “The challenge was that during the pandemic we could never meet face-to-face with the architect or contractor. The entire development process took place during Zoom meetings and phone conferences. We even had to drop off samples at the homes of the architects, because everyone’s offices were closed. But thanks to the professionalism and dedication of this amazing team, the project went seamlessly.”

Younger is a tenured building envelope specialist with IMETCO, based in Georgia, which is a leading manufacturer of premier, high-performance metal roofing, wall, deck, and edge systems that provide a virtually limitless realm of aesthetic possibilities. With a reputation for managing highly complex building envelope projects, IMETCO was able to provide a roofing solution capable of meeting the university’s strict Factory Mutual (FM) insurance requirements while fulfilling the ambitious aesthetic goals of architectural firm GBBN Architects, with offices in Pittsburgh, Beijing, Cincinnati, Louisville, and Minneapolis.

Merging Aesthetics with Performance 

GBBN works with visionary organizations and prides itself on combining creative tenacity with technical mastery, a global perspective, and a laser focus on fulfilling each customer’s objectives as flawlessly as possible. Their team on this project included Stephen Mrdjenovich, Marc Janty, Matthew Plecity, and Phyllis Kim.

Younger recalls, “GBBN knew they wanted a graceful transition from the old, brick, gable-roofed building to a more modern structure. The architectural team loved the look of zinc, so trying to replicate that in a heavy .050 aluminum cladding system was the aesthetic requirement for this project.”

The architects chose a Cerulean Shadow finish from IMETCO’s da Vinci Collection of prints for both the roof and walls. The finish provides a subtle blue tint that mimics the aesthetic of brushed/aged metal with a faint grain pattern.

From a functional perspective, both the roof and wall system needed to be able to withstand the wind-driven rains and freeze/thaw cycling that characterize Erie’s weather. The 10,000 square-foot addition required just over 8,500 square feet of roofing in addition to nearly 1,300 square feet of wall cladding.

The Roof 

In order to meet stringent FM requirements, the architects chose the industry-leading Merchant & Evans/IMETCO ZIP-RIB standing seam metal roof system. One of the toughest and most thoroughly tested standing seam solutions on the market today, the ZIP-RIB system is AAMA 501.1 rated for wind-driven rain, ASTM E-1592 rated for wind uplift performance, ASTM E-1646 rated for water penetration, ASTM E-1680 rated for air infiltration, ASTM E-2140 rated for water penetration and vertical load, with UL-90 Uplift, UL Class “A,”  UL P-XYZ assemblies.

The ZIP-RIB roof panels are secured by concealed anchor clips that eliminate concerns about structural penetration, which might otherwise lead to leakage with Erie’s extreme thermal variations. By allowing for thermal movement, the anchor clips enable longer panel lengths than with conventional roof systems, for a ridge-to-eave installation that provides clean, unbroken lines while eliminating the possibility of leaks at end-laps.

The Walls

To ensure aesthetic compatibility while maintaining the highest level of performance, the ZIP-RIB system’s standing seam vertical wall panels were chosen. The versatile ZIP-RIB system enabled the architects to precisely match the gauge and depth of the wall panels to those of the roof panels.

For aesthetic enhancement, IMETCO’s Latitude metal wall system was chosen for the cladding. This system allows for both vertical and horizontal configurations, which can be mixed and matched for dramatic results. The Latitude system was installed using 12-inch wide, concealed, heavy-duty clips and fasteners, which enable limitless thermal movement.

It’s All in the Details

GBBN has a well-deserved reputation for setting high expectations for its partners, and this project was no exception. Of special interest was their aesthetic demand for a gutter-free exterior. GBBN envisioned a roof that flowed without disruption into the walls. Given Erie’s heavy snow accumulation, the request made sense from both a functional and aesthetic perspective.

The building’s design features roof panels that come down at an angle. The ultimate goal was to line them up precisely with the seams running vertically down the wall. Says Younger, “This was extremely tricky. Things would need to align perfectly.”

He continues, “What was needed was a custom knee joint. We started the process with paper models that we shared via Zoom calls. The way it would work is that when water hits it, it would tumble around the joint and into a cistern. The college could then recycle and use the water.”

No matter how well-crafted the design, the project would also require the expertise of an installer with a long and proven reputation for excellence in the field. They chose Patrick McCreary of McCreary Roofing Company, Inc., based locally in Erie.

A fifth-generation family business, McCreary Roofing is a member of Roofers Local 210 and Sheet Metal Workers 12. Younger recollects, “I dealt with Patrick’s grandfather 40 years ago, and all these years later the quality of McCreary’s work is the best there is. Period.”

According to Younger, a knee joint detail was installed preliminarily in the field so that the architects could visit, inspect, and make certain the alignment met their expectations. McCreary and his team did it right the first time, and the finished project speaks for itself.

The integration between the ZIP-RIB standing seam roof and walls panels is flawless. The deeply fluted verticals are punctuated with an occasional horizontal line to break up the monotony with a dramatic flourish. The color, gauge, and depth of the roofing and wall systems are a perfect match, creating a modern aesthetic that complements the original brick structure.

As a finishing touch, GBBN required the installation of an IntelliScreen air-barrier, water-shedding exterior cladding system. The result is a water-tight design that is as beautiful as it is functional.

Younger concludes, “It’s hard to imagine, but despite our inability to interface more directly with the architectural team, the roof and wall design and installation went smoothly from day one, without a hiccup…I’ve served this industry for 42 years, and this project just might be the icing on the cake.”