SANDERS ESTES UNIT

Entry Form . . . . . . . . . . . . . . . 02

Client Introduction . . . . . . . . . . 03

General Information . . . . . . . . . 04

Uniqueness . . . . . . . . . . . . . . . 06

Challenges . . . . . . . . . . . . . . . . 08

Safety . . . . . . . . . . . . . . . . . . . 16

Testimonials . . . . . . . . . . . . . . . 18

Project Photos . . . . . . . . . . . . . 20

Member Involvement . . . . . . . . . 24

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Sanders Estes Unit is located on property owned by the Texas Department of Criminal Justice . Construction was completed in August 1989 on the 1,000 inmate penitentiary .

The facility is designed to focus on offender rehabilitative programs to the fullest extent possible . The GEO Group networks with local, state and federal resources to maximize the amount of programs available to the offenders . The program scenario balances the need for facility security with offender rehabilitation . Each offender is engaged in a full-time mix of employment, employment training, education and counseling . The GEO Group provides programs that have the goal of reducing recidivism .

The overall design of the facility allows for direct line-of-sight observation, which is further enhanced by a CCTV System . Facility design allows for cost-effective utilization of security staff and thereby allows for enhanced program activities without significant budgetary impact. By design, the prison allows for the 1,000-offender population to be divided into manageable, cohesive groups . Design and construction range in techniques from normal office or educational facility type construction to secure housing units that consist of multiple occupancy cells, with a single cell occupancy secured housing unit . Program areas include classrooms, a general and legal library, teachers’ areas and support space . A gymnasium, vocational shops, a maintenance shop, a central kitchen and dining hall, central laundry facilities and medical facilities are included .

Property owner: Sanders Estes Unit 1100 Highway 1807 Venus, Texas 76084

OWNER: Texas Department of Criminal Justice

#2 Financial Plaza Suite 400 Huntsville, Texas 77340

ARCHITECT: Amtech Building Sciences, Inc. 3300 S . Gessner Suite 118

Houston, Texas 77063

FACILITY MANAGERS: The GEO Group, Inc . World Headquaters

One Park Place, 621 Northwest 53rd Street, Suite 700

Boca Raton, Florida 33487

contractor: Castro Roofing of Texas, LP

4854 Olson Drive Dallas, Texas 75227

ROOF REPAIR and REPLACEMENT FOR PRISON COMPLEXROOF SYSTEM TYPES: Modified Bitumen and the installation of new Lightweight Insulated Concrete Deck.

SCOPE OF WORK: (LOW-SLOPE)LOW SLOPE ROOFS - The re-roof consisted of removing the existing ballasted EPDM roof system down to the structural concrete deck . A temporary torched applied membrane was applied directly to the concrete deck prior to the installation of the NVS lightweight system and then covered with the new Modified Bitumen roof system.

LIGHTWEIGHT INSULATED CONCRETE DECK - • removal of all aggregate, dust and dirt from roof surface

• aggregate removal was performed with wind rows to prevent the loose laid EPDM membrane from blowing off

• tear-off of all materials down to structural concrete

• installed a temporary torch grade membrane directly on the structural concrete

• installation of 1/8” per ft . full tapered lightweight insulated concrete deck system to provide positive drainage over entire roof surface

MODIFIED BITUMEN MEMBRANE - • mechanically fastened into light weight insulating concrete specified

fiberglass base sheet

• installation of torch grade Modified Bitumen base sheet

• installation of torch grade Modified Bitumen cap sheet

OTHER: • New 24 and 26-GA stainless steel sheet metal trim

• fall-protection per OSHA requirements

• custom wood blocking

• all new lightning protection so the entire building became certified

• french drains installed at three locations

• all thirty-seven existing HVAC units were removed and replaced with new HVAC units

• existing thirty-eight skylights and skylight curves were removed and replaced with new skylights

• new citura expansion joints were pre-fabricated per exact measurements and later installed

• extra “life-safety” precautions were coordinated with prison personnel due to the complex nature of working around prisoners and staff at a state operated prison

SIZE OF PROJECT: • SBS Modified Roofing = 183,600 sq. ft.

• Total Square Feet = 183,600 sq. ft.

• Length of project: = 380 calendar days

• Completion date: = May 2008

PERCENTAGE OF SELF-PERFORMED WORK: • 56% Castro Roofing of Texas

• 14% NVS Lightweight Concrete (G.L. Nettles, Inc.)

• 28% HVAC Replacement (Treviño Mechanical)

• 2% Lighting Protection (Bonded Lighting Protection)76

Access and operations proved to be difficult

due to the nature of the building . Construction

could not interfere with the daily activities of

the facility’s prisoners and staff . The fact that

Sanders Estes Unit is a prison that focuses on

Adult Basic Education, GED, Fundamentals, Life

Skills and Vocational Programs, signified various

dilemmas for our presence . Appropriately, the

prison demanded a higher standard when it came

to safety both for its prisoners, staff and visitors .

All the proper precautions were taken to ensure

that no potential weapons were left out within

prisoner reach .

Castro Roofing coordinated all work in such a

manner that facility operations continued with

minimal disturbance . This fact translated into

the importance of being extremely cautious and

demanded that physical and visual distractions be

kept to a minimum . Due to the sensitive nature of

working on an operational prison, the noise level

was also a concern, especially during demolition .

Weekly meetings with prison staff was necessary

as communication was essential .

Castro Roofing fully complied with all requests

during demolition and construction, was pro-

active and accomplished the goal in keeping the

prison’s daily regiment going without interruption .

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Armed to the Teeth!

High Security Level

THE CHALLENGE

THE CHALLENGEThe Sanders Estes Prison re-roofing project was very difficult, not only to estimate but also to execute. The five separate buildings were comprised of 183,600 sq. ft. of multiple roof elevations with tapered NVS Lightweight pour.

Superb communication and interaction between our crews and sub-contractor ensured operations at the prison were not interrupted. The 183,600 sq. ft. of low-slope roof required a tapered NVS Lightweight deck to create positive drainage. This demanded a synchronized effort between the installation of the new NVS Lightweight deck and the SBS Modified Roof System which maintained the building water-tight during tear off and the other various phases of work.

A special interest is always shown in a huge project such as that of Sanders Estes Unit. As the bid date approached we analyzed the various phases and the requirements set forth in the documents provided by the State. This was necessary in order to properly understand details in the scope of work and insure adequate quotes. We reviewed the scope to analyze all the client’s special requirements not only involving roofing material but also taking into account site restrictions, construction safety issues, environmental concerns and safety of the Unit’s inhabitants. Out of several bids that were submitted, Castro Roofing of Texas was chosen to be awarded the project.

It was pretty obvious to all that this project would be a challenge. Due to the peculiar purpose of the building special attentions had to be paid and every base needed to be covered.

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York HVAC Unit

No Time to Spare!

Commanding the Lightweight Pumps

Dealing with a facility that houses 1,000 convicted criminals posed more then the usual road blocks for a construction project . The prison is also a workplace for doctors, nurses, dentists, cooks, guards, teachers, librarians, not to mention the warden . However, being made aware of the special circumstances assisted in the scheduling of this project .

Other obstacles were of logistical and technical

nature . The prison is approximately 70 miles

southwest of Dallas, Texas and presented the

crews with almost 3 hours of daily driving to and

from the job site .

Weather also presented a problem for the crews,

with heavy rains during what should have been

summer . 20 rainy days in May, 20 in June, and

15 in July proved to be a tremendous set back

for the roofers . Not only was it impossible to get

on the roofs to lay down material, but also no

heavy equipment such as booms and semis could

be moved in because of the surrounding mud and

sludge . This pushed the project’s duration back to

380 days .

Prison Demands

Logistics and drive time

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Temporary Membrane

NVS Lightweight Pour

Installation of Torch Modified Base Sheet

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Due to the job’s multiple buildings and tight schedule, there was need for exact coordination between the crews and the sub-contractor during the installation of the NVS Lightweight deck. Even with this, some days work on the roofs was prohibited due to inmate behavior or last minute issues .

However, before tear off could even begin, 39 HVAC units totaling 20 tons had to be removed . Once tear off started, special precautions had to be taken to ensure a water-tight environment for everyone inside . This was not easy due to that rainy Texas summer. Before proceeding, the HVAC units were replaced, and then roof work was resumed .

Sub-contractor and scheduling

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Mechanically Fastened Base Sheet

Hard at Work!

Expansion Joints

Because of the special circumstances surrounding the project daily cleanup was necessary . Trash and metal scraps could not be left around the job site for fear of being used against the guards, so proper waste disposal became a key element in the project’s success . Although it cut into the crew’s work time it was an absolute must for everyone’s safety .

· Protective wear (gloves, clothing and shoes) · Hard hats · Eye protection · Back injury protection · Heat exhaustion · Flammable liquids and combustibles · Fire safety · Operating the kettle · Hand tools · Prison safety requirements · Practical jokes on the job site

With roof construction underway, Castro maintained OSHA Safety requirements and Castro’s safety director had 2 weekly onsite meets to keep the crews sharp and focused . There were no injuries experienced during the 380 day project!

Safety in a prison

WEEKLY tool box talks

No injuries!

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Safety Netting

Safely Harnessed!

Caution! Steep Fall!

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Back view of Estes Prison

Raising Materials to Commence Roof installation

Primed Structural Concrete Ready to Receive the Temporary Roof

Lightweight Concrete Pour in Progress

Demolition and Removal of Existing Roof

Newly Applied Lightweight

Lightweight Concrete in Progress

Lightning Protection and a Nearby Scupper

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Counter Flashing to a Coping Transition

Newly Poured Lightweight Concrete

Sopralast Metal Flashing

Newly Replaced Skylight

Two-coat Safety Yellow Gas Lines

New Stainless Steel Collection Heads

Gas Lines

Down-spout “hugging” the Wall

This project was self-performed by Castro Roofing of Texas, L.P.

Under Castro Roofing of Texas, L.P. contractor’s scope of work, the following NTRCA member contributed to the

success of this project:

Castro Roofing of Texas, LP. 214 .381 .8108 · 800 .759 .1879 · Fax 214 .381 .8109

www.CastroRoofing.com

Servicing: Austin • Dallas • El Paso • Fort Worth • Houston • San Antonio Helping Clients Succeed

bradco SUPPLY

berridge MANUFACTURING

dfw roofing supply, LLC

olympic MANUFACTURING GROUP

soprema, iNC

SANDERS ESTES UNIT

Castro Roofing of Texas, LP. 214 .381 .8108 · 800 .759 .1879 · Fax 214 .381 .8109

www.CastroRoofing.com

Servicing: Austin • Dallas • El Paso • Fort Worth • Houston • San Antonio Helping Clients Succeed