Insulated Panel Developed for Low-Slope and Flat Roofs

Originally published by: Design and Build With MetalNovember 29, 2017

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Many large low-slope commercial-industrial and cold storage buildings are built using traditional steel roof deck assemblies. This type of roof is comprised of a roll-formed steel substrate under multiple layers of rigid foam insulation which is then covered with a single-ply membrane roof sheet. To Bill Lowery, president of All Weather Insulated Panels, roofs constructed in this traditional manner are obsolete.

“It’s time for the North American construction industry to undergo a paradigm shift,” Lowery said. “I see the way these roofs are installed and realized that there are superior, cost-effective solutions available simply by applying newer composite technologies.”

With that in mind, Lowery developed OneDek as a revolutionary insulated panel composite for low-slope and flat roof applications. OneDek, Lowery said, will save time and labor costs during construction while providing superior properties, including resistance to deflection, diaphragm shear, fire and higher R-values per inch compared with most insulation boards available on the market.

OneDek-installBy producing the insulation and the steel substrate at the factory, OneDek panels eliminate the need to add insulation on the job site. This time-consuming step has installers manually staggering the insulation board layers and then securing them with thousands of long length mechanical fasteners to the steel deck substrate.

With the use of a “vacuum lifter,” OneDek panels are easily set in place over roof support steel and engaged via roll-formed tongue-and-groove joinery. Securing the panels to joists or purlins requires far fewer fasteners and takes less time.

The composite nature of the OneDek assembly allows for longer spans between supports and, unlike an insulation board substrate, OneDek panels are highly resistant to damage from foot traffic during and after construction. The ability to meet diaphragm shear requirements makes OneDek unique as a composite utilizing steel facings and a polyisocyanurate foam core. But the benefits of OneDek don’t stop there.

The panels can be produced in thicknesses ranging from 2 to 6 inches, offering an R value up to 50. The exterior coated steel provides an ideal substrate for either mechanically fastened or adhered white TPO and PVC membrane waterproofing. The interior steel facing of OneDek comes with a white factory-painted finish, which is easy to wash and highly reflective, thereby reducing lighting requirements. “Just another benefit that comes with OneDek,” said Lowery. “Fewer light fixtures alone provide only a portion of the savings for a 150,000-square-foot project, but then add that to all of the other advantages, including installation time and superior overall performance, OneDek really does makes a difference.”

Lowery is so confident about the integrity of the OneDek roof assembly that AWIP offers an industry-exclusive, 20-year, top-to-bottom Roof System Weathertight Warranty. This warranty covers the membrane roof. For building owners, that's a huge benefit. 

“In the U.S. construction industry, we have to lead the horse to water and then entice it to drink,” said Lowery. “When it comes to OneDek, they’ll be happy they did. It’s economical, faster and better.”

As the new product demonstrates, AWIP is an innovator in the design, construction and advancement of insulated metal panels. The company was founded by Lowery in 2004 and currently has two state-of-the-art, continuous-line manufacturing facilities. One is located in Vacaville, CA, with the second in Little Rock, AR.