By Heidi Ellsworth, HJE Marketing – Architectural West, March/April 2004
California is home to some of the most iconic and modern commercial buildings in the West. However, among the sleek contemporary designs, the Chet Holifield Federal Building stands out with its distinctive ziggurat shape. Located in Laguna Niguel, this federal building showcases a silhouette reminiscent of ancient Babylonian architecture, creating an unmistakable presence on the Orange County skyline.
Originally designed for Rockwell International, this structure is now a recognized landmark that hosts a variety of federal agencies. Recently, the building underwent an extensive exterior remodel, including the installation of a new roofing system that highlights modern roofing technology and environmental efficiency.
Architectural Significance of the Chet Holifield Federal Building
The Chet Holifield Federal Building is unlike any other structure in California. Its stepped pyramid design, inspired by ancient Mesopotamian ziggurats, breaks away from the state’s typical modern architectural trends. This unique form has earned it the nickname “The Ziggurat” among locals. Built in the 1970s by the aerospace company Rockwell International, the building was initially intended to support the company’s operations. However, it was eventually acquired by the federal government and transformed into office space for multiple federal agencies, including the Internal Revenue Service and the National Archives.
The building is not only a functional space but also an architectural marvel. The use of the ziggurat shape was intentional, reflecting both aesthetic appeal and structural efficiency. With its terraces and distinct profile, the building optimizes space while creating a striking visual landmark in southern California. Today, it remains one of the most unusual and recognizable structures in Orange County.
The Role of the General Services Administration (GSA)
As the third-largest building managed by the General Services Administration (GSA), the Chet Holifield Federal Building is crucial to the federal government’s presence in California. The building houses numerous federal tenants and includes essential facilities such as a service building with offices, workshops, garage bays, and a central plant for the building’s cooling system. The GSA’s role is to manage and maintain the building and ensure its sustainability and efficiency.
Remodeling the Chet Holifield Federal Building: A Massive Undertaking
The remodeling of the Chet Holifield Federal Building was a long-term project aimed at modernizing and improving the structure’s efficiency while minimizing disruptions to its occupants. Given the building’s federal status, the government required that any remodeling work meet strict guidelines, including environmental compliance, minimal disruption to tenants, and long-lasting solutions.
The Roofing Challenge: Meeting Federal Standards
One of the most significant aspects of the remodeling project was the roofing system. The federal government’s request for proposals (RFP) outlined specific requirements, such as a roofing solution with a 20-year guarantee and minimal impact on daily operations. This included controlling noise, reducing odors, and ensuring safety for the building’s occupants.
Douglas Keith, the assistant project manager/project superintendent for Western Roofing, highlighted the importance of selecting a roofing product that met these criteria. “For this job, we knew we needed a roofing product that would work while having a very low impact on the tenants. We recommended Polyglass SA self-adhered roofing membranes with ADESO™ technology. It fit the bill for what we had to do,” said Keith.
The Polyglass SA Roofing System: A Technological Advantage
Polyglass SA self-adhesive membranes with ADESO Technology were developed based on Polyglass’ long and worldwide experience in the commercial and industrial roofing markets. The membranes comprise the latest in asphalt adhesive technology, as well as proven weatherproofing compounds, featuring smooth and mineral granule surfacing, available in various colors as needed.
“Western Roofing is always on the cutting edge,” confirmed Keith. “We were one of the first roofing contractors on the West Coast to use ADESO on a regular basis. With projects like the Travis air base and BART stations on our list of ADESO projects, we knew that ADESO would be the best system for the Holifield Federal Building.”
ADESO Technology: Revolutionizing Roofing
Polyglass U.S.A., Inc., a leading manufacturer of roofing and waterproofing systems, has positioned itself at the forefront of commercial roofing technology with its ADESO membranes. Polyglass SA self-adhesive membranes with ADESO Technology include Elastoflex SA, Polyflex SA, Xtraflex SA, Polyall SA, Polyram SA, PolyKool SA, and Polystick underlayment roofing products.
Polyglass SA self-adhesive membranes with ADESO Technology are manufactured utilizing glass fiber or polyester reinforcement, with a “true” APP, SBS, or TPO compound on the top weathering side and an aggressive self-adhesive formulation on the bottom side of the reinforcement. The self-adhering properties of the built-up membranes provide the perfect alternative when traditional adhesives or propane torch techniques are not desirable or are prohibited.
“The self-adhesive membranes do not use any kettles or torches, so there is no impact on the tenants,” Keith noted. “No noise and no smell. The lack of hot kettles and torches was a real selling point. Employees were not disturbed and the safety of the project was enhanced. We pride ourselves on our safety record. Being able to roof without kettles and torches is a large step forward to a safer work area.”
The Design/Build Team: CRC Consulting Group and Western Roofing
The remodeling project at the Chet Holifield Federal Building was managed by a dynamic design/build team, consisting of CRC Consulting Group and Western Roofing. CRC was responsible for the design and specification development, while Western Roofing served as the project manager and prime contractor. The collaborative approach of this team ensured that the project stayed on track and met the government’s strict requirements.
The Importance of a Collaborative Design/Build Approach
Michael Perry, vice president of CRC Consulting Group, emphasized the benefits of a design/build team. “Having a design/build team is a great advantage because everyone works together to achieve positive results,” said Perry. This approach allowed the team to adapt quickly to any challenges and maintain efficient communication throughout the project’s duration.
The Roofing Installation: A Complex and Efficient Process
The installation process for the roofing system was extensive. Beginning in March 2003, Western Roofing’s crew worked meticulously to complete the installation. The team installed approximately 2,800 squares of Polyglass ADESO membranes across various floors of the building, using innovative technologies like FASTLap® and SEALLap® Ultra.
Scaffolding and Security Measures
Given the federal nature of the building and its high-security requirements, the team faced unique challenges. Strict security protocols were implemented, including thorough background checks for all workers. To minimize the need to enter the building and ensure continuous access to all levels, Western Roofing installed scaffolding around the front of the building. This approach allowed the crew to work efficiently while adhering to the building’s security measures.
Roofing Installation Techniques: Ensuring Minimal Disruption
To comply with the government’s mandate of minimal disruption, Western Roofing applied several innovative techniques. The use of Polyglass’ ADESO membranes was crucial, as it eliminated the need for noisy equipment and reduced the potential for odor. “We knew that the use of Polyglass’ ADESO membranes would allow us to maintain the building’s air quality and keep noise levels down,” noted Keith.
The team also took extra precautions, such as covering intake vents in work areas to prevent any particles or smells from entering the building’s ventilation system. These measures ensured that the building’s tenants could continue their daily activities without interference.
The Benefits of Polyglass SA Self-Adhesive Membranes
The Polyglass SA membranes used in the project featured several innovative properties that made them the ideal choice for this federal building remodel.
FASTLap® Technology: Seam Integrity
One of the key features of Polyglass SA membranes is the patented FASTLap® technology. This system creates granule-free end laps that allow for a tighter seal between rolls, reducing the likelihood of leaks. This technology not only enhances the roof’s integrity but also saves time during installation, reducing labor costs and eliminating the need for repairs.
SEALLap® UltraTechnology: A Secure and Efficient Solution
Another significant technology integrated into the Polyglass SA membranes is SEALLap® Ultra. This patent-pending adhesive treatment provides a highly secure seal between membrane overlaps. Activated by heat and pressure, SEALLap® Ultra ensures an immediate and permanent bond, even at low temperatures. This technology allowed the installation team to complete the roofing process efficiently while maintaining the building’s structural integrity.
Environmental Impact and Energy Efficiency
California’s regulations and emphasis on sustainability played a significant role in the choice of materials for the Chet Holifield Federal Building. The Polyglass SA membranes, with their low-VOC formulation, aligned perfectly with California’s energy efficiency goals. The use of these membranes not only reduced solid waste but also minimized reliance on petroleum-based products, supporting the state’s push for environmentally friendly and energy-efficient construction practices.
Polytherm® Foam Insulation: Enhanced Energy Performance
In addition to the roofing membranes, the remodel included the use of Polytherm foam insulation, an ISO system that enhanced the building’s thermal efficiency.
“The system included Polytherm® foam insulation, an ISO system with taper system applied with Ashland adhesives, two layers of Adeso Elastoflex SA V base and one layer of Adeso Polyflex SA P cap,” Keith continued. “The second floor had 1,260 squares of ADESO roofing, third floor, 781 squares, fourth floor, 115 squares, fifth floor, 96 squares and the sixth floor, 126 squares,” Keith noted. “It was a huge job but the job looks tremendous. The seams are straight and the roof is really beautiful.”
This insulation system worked in tandem with the ADESO membranes to reduce the building’s energy consumption, leading to potential rebates and energy savings for the government.
The Future of Roofing Technology: Polyglass’ Commitment
Polyglass continues to innovate in the roofing industry, pushing for safer and more efficient solutions for commercial buildings. With ADESO Technology, Polyglass offers a range of membranes that provide long-lasting durability without compromising the environment or building safety. Natalino Zanchetta, executive vice president of U.S. operations, highlighted the importance of these innovations, stating, “Self-adhesive membranes are leading the market as the new ecological roofing product due to the lack of VOCs and solid wastes along with the lack of petroleum products in the installation process.”
Conclusion: A Successful Remodel for the Chet Holifield Federal Building
The remodel of the Chet Holifield Federal Building stands as a testament to the effectiveness of Polyglass’ roofing technology and the collaborative efforts of CRC Consulting Group and Western Roofing. With a design/build approach, innovative roofing products, and a focus on sustainability, the project successfully modernized this iconic federal building while meeting all government requirements.
The building’s new roofing system not only enhances its appearance but also ensures long-term protection and efficiency. The Chet Holifield Federal Building remains a remarkable architectural and functional landmark in Laguna Niguel, showcasing the integration of modern technology with historic design.