The process is simple, pre design a 4000 square foot custom retractable enclosure, order the custom 29 component parts in the proper quantity and color and make sure that its manufactured, shipped and installed within 4 weeks time. It was surely a task that most would run from, but we accepted the challenge…. And we succeeded. It was quite a task in manufacturing and preassembling 25 sections of our Roll-A-Cover enclosures in a small town outside New haven, Ct and staging them for shipment then crating them on 4 56’ flat beds ready for a road trip through some of the roughest roads in New England, the City. But, the challenge was what it was, a challenge and we conquered with flying colors. Of course stress, anger, a lot of cussing occurred but we knew that we had a calling and that was to fulfill a request from one of the most prestigious Hotel companies in the World, The Ian Schrager Group, and do it with a smile. We knew that someday we would rest, but till then, it was all work and no play….Worrying about being able to meet the weekend deadline that was facing us and not being the company that would hold the entire organizational process of delivery; craning and installation beyond our projected install date took our management to new levels of organization. Challenges are what builds companies and allows them to learn today for the next major design request that will come tomorrow.

Open	Closed

As we prepare the facility and staff for the onset of thousands of pounds of custom extrusions and components that are specific only to our custom enclosures, our staff is completing several other enclosure projects at their arrival

Kevin, a 14 year veteran in the enclosure industry has received the cad drawings with specific cutting requirements for each rafter section. The precision and care that needs to be taken during the cutting and machining of the rafters is the most critical part of the manufacturing process.

Joe, our CNC technician is following Kevin’s lead with the drilling and milling of each rafter which usually receives between 8-14 different size guide holes and layouts. This tedious and technical process allows our purling and gussets to stay in alignment during the assembly process.

Our machining center is controlled by the technical advancements of CAD and our VP of Engineering and Design, Kerry Taylor. He develops the model of the rafter requirements with the CNC system and transfers it to the system for precision cutting and drilling. Joe, our senior technician controls the machines precision and monitors the process during its functions. Joe also has the capability of redesigning or formulating a cutting or drilling requirement through his touch control keyboard. His experiences and craftsmanship has brought him to Roll-A-Cover as a key player with our product quality and system control process. It automatically pulls the required milling and drilling bits from a holder and processes its functions electronically. It’s quite an amazing piece of equipment that has given Roll-A-Cover an industry edge with precision and quality.

Jason, one of our top fabricators and installers is showing how we then take each rafter and component and label them so that during the process of assembly the staff members have a guide to each added component that needs to be installed on each rafter. We have dozens of small parts that never seem but are critical to the enclosures makeup. They are special to Roll-A-Cover products and can’t really be shown at this time.

  The walls were all pre-glazed with a ¼” polycarbonate UV coated material with custom sliding windows. Being stacked ready to be sent to their holding area. The walls as well as the roof system are pre-assembled for this project due to the time limitations and also space issues within New York City.

Once the roof sections are assembled then the walls are slid into place with our solid aluminum gusset that has been tested at 65,000 lbs for deflection and didn’t even move an 1/8” in a spread test. We drill and tap each gusset in house ready for assembly.

Jason Jr. is one of many that are precutting the smaller parts such as purlins, caps and pressure plate components for the completed fabrication of each section. Jason’s respect for precision and youthful excitement has made Jason a key player within the facility and in the field during our installs.

The roof systems are very heavy with Dave Pate, our VP of Manufacturing, assisting a few team members in the plant during assembly of the roof and walls.  This process is delicate because of the weight and also technical due to the connection components need to be aligned in such a way that the system maintains its required roof and wall configuration and shape.

The excitement starts. Two days before the install process takes place the trucks that are going to take away the loaded trailers arrive. They will be apart of the loading process because they also have to make sure that while they are traveling the Roll-A-Cover enclosures aren’t sprawled across the highway.

Bruce, one of our team players is all smiles because the sun is out and the 20 degree days just past. Our small lift will assist us in loading the sections onto the trailers. With Bruce’s keen eyes and steady hands as the operator, we will be loaded up in no time.

The loading is critical. We can’t exceed 13’ in width and 13’ in total height. We have to stack 4 sections per   rise and make sure that they make it to the city in one piece. Yes, this was probably harder than the install process itself.

As an owner of his own trucking company, his excitement lied with being part of this project and many others to come.

Jack and Kevin, who are related to Jason Jr., are sharing a bonding moment. Of course jack wished that he was as young and strong as Kevin during the lifting process but Jack was able to hold his own. Jack, from our management team has chosen to join our plant team during the loading process. As a company, everyone wears 10 hats. It’s what sets us apart in the industry.

The loading process is tedious and delicate. As we prepare to complete one of the flat beds loading process we then proceed to the next trailer.

Bruce, with precision, lifts each section into place.  Each section weights about 1100 lbs.  Without this crane we would have been limited on the height that we could have stacked the system ourselves.

 Phil, who enjoys being with us and being apart of the team, is always there with a smile….

Jack tries to manhandle a section without a complaint.  Because he is a white collar kind of guy, he could have eaten a whole pizza for lunch.  I am sure that he wishes that he had a hot tub after a long day in the field.

Supporting the sections was even a bigger task once loaded. Making sure that they stayed stable on the flat beds while traveling through the pothole ridden city of New York was a task that our carpenters worked hard on. Kerry, who took charge of this project made sure that there wasn’t a shake to be had. The systems were tight and ready to roll when the men were done.

Final trailer was being loaded and secured ready to travel.

Time to go as the caravan of 4 rigs and wide load back up vehicles followed. It will be a 5 hour ride to the City on a Friday eve waiting for sunset on Saturday so that they could drive down Lexington Ave.

: … and here we go, heading into the city, one rig at a time. Once each rig was unloaded the next rig would travel in and settle down in front of the crane ready to be unraveled from the strapping and lifted to the roof.

As the rig drives into place with the Roll-A-Cover enclosures, the crane is preparing for its arrival.

With the closing of Lexington Ave, the space that was given by the City and Community allowed the crane and rig to have a safe place to rest during this process.

Kerry Taylor, the VP of engineering and Design for Roll-A-Cover has played a key role in the design and site preparedness of the roof top at the Gramercy Park Hotel. He’s looking over the roof as he checks for final concerns prior to the system being craned. Kerry’s tremendous knowledge of construction and his Roll-A-Cover products has given the designers from the Hotel support during all phases of this project that were unprecedented. His calming personality allowed for a precise design to be achieved as well with his support from his co-staff at Roll-A-Cover.

The riggers attach the cranes boom to the harnesses that will support the enclosure as its being lifted into the air.

Dave Moore, the construction supervisor on the project has been an important part of this entire project. His organizational support and planning has allowed the Roll-A-Cover enclosure to be on time as planned.  Always on the phone is what Dave is known for... Preparing the next step.

Flagmen are just as important as the installers.  Protecting the onlookers as the road was closed was critical and also a precaution that was necessary. They flanked several roads around the Complex so that trespassers were protected from crossing through a bearer that was a controlled area.

As the crane settles in for the weekend on Lexington Ave…

…….Harold, the crane owner, keeps everyone organized with two cell phones.  Most of us could of used 3 in each ear that day but 2 were all we could handle.  It was critical to have the roof support be in touch with the crane operator.  He could not see where to direct his boom.  It was quite a feat which we thank their entire company for providing their services with such professionalism and precision.  It allowed the process to flow all that much smoother.   

So, it’s happening, the first section is being craned to the roof. 17 Stories in the air, it was like threading a needle in the middle of Lexington Avenue. As the section goes higher….

…and higher…

…and higher…

…and higher…

…and higher…

…and higher…for the men that are awaiting its arrival.

Prior to the installation of each section, Roll-A-Cover custom tracking system was installed. Now as the section is slowly being dropped into place, the team of Roll-A-Cover specialist position themselves on the 17^th and 18^th story area so that they could then manhandle it into place.

The settlement of the section with precision by the crane operator and the roof controller was key on this project.

As the system starts to settle into place everyone takes their position.

The question was that, is it cold on the roof? If you ask Kevin and Jason they would tell you that they would rather be on the scaffold 17 stories in the air then on a cruise through the Caribbean. Well, maybe not but they are doing a fine job and with a short break till the next section arrives they have time to warm up

Another section is set into place ready for the next…

With everyone intrigued by Roll-A-Cover’s unique rolling concept, their excitement to see the completed project in whole is growing with every lift by the crane.

Here comes another section… Its funny how when you look up you have a tendency to sneeze, well, everyone on the street was sneezing it was quite a site. The onlookers were enjoying the process as the crane never stopped lifting.

The riggers are preparing for another lift

With Dave being on edge about the enclosures successful completion on Sunday night, Michael Morris, The president of Roll-A-Cover takes a minute as he shows his comfort and enjoyment that he had with Dave during this whole process.

watching lift of a section hover over the roof then….poof its gone.

The riggers are holding on from the ground as the section is shifting with the wind. Nobody wanted to see any of the enclosure roll into someone’s penthouse suit by accident so a lot of protective measures were in order.

On the south side of the building with three sides being totally wrapped by Roll-A-Cover, the cranes start the process. And it’s up on the roof within minutes.

being dropped into place was so critical but the surgical hands of the operator allowed this precision to occur.

still being dropped..

and dropped….

A side view from the roof top during construction. The plans for the roof are quite a surprise to everyone, but as we know the Ian Schrager group, nothing is ever completed without the finest of everything, from design, to plantings to artwork.

This area is on the North side and is a fixed area. The space wasn’t really worth having it roll open based upon the hundreds of feet that does so we designed a fixed enclosure system with a custom walkway.

 Another angel of the main section closed during construction. The system is extremely high and offers a feeling of comfort that will be an area that will have the best of social gatherings.

The south side of the enclosure still under design and construction.

Another angel showing the south side riding into the east side that overlooks Lexington Avenue. It’s a wrap around enclosure which provides a million dollar view on three sides.

As one of the final sections gets sent to the roof….

as one of the final sections gets sent to the roof….

Being greeted by the Doorman at the Gramercy every time you enter with their cordial personalities was a weekend pleasure. They were not only a valuable aspect of this project but also a tremendous help in maintaining a safe and protective passage for their quests while this “Extreme rooftop makeover” took place. Good people with a lot of class.

An outside view with some of the sections open is always an exciting part of the project. Waiting to see the final results will be what we all are waiting for.

Kevin and David, exhausted from the hard days work and partially frost bitten from the cold, still stay in tuned to what section is about to arrive. Being 110% all the time is what makes Roll-A-Cover a choice company to work with.

An outside view with some of the sections open is always an exciting part of the project. Waiting to see the final results will be what we all are waiting for.

Joe is resting and trying to keep warm while waiting for another section to arrive. 

another angle looking north up Lexington Ave of the crane performing another lift.

and its up…

up…

and now its being set into place

Dave couldn’t just play group organizer, he had to join the working team. We were all quite impressed with his excitement as this process was occurring.

Mike Lightfoot, VP of sales for Roll-A-Cover, enjoys a private tour with one of the Gramercy Park Commission members. This young lady AIrene, offered Hot Coffee to the grounds team and was always there as support. The Gramercy Park Homeowners Association provided tremendous amount of support to the efforts of The Ian Schrager Group during this street closing and craning process. Its not often that neighbors are advocates of extreme construction projects, but as they know, the Gramercy is one of a kind and their respect for the Gramercy Park Hotel is treated by the management team at the hotel as a circle of friends which look out for each others successes and comfort.

Dave Pate, an 18 year veteran with the owner of Roll-A-Cover and one of the highest regarded fabrication and construction designers and installers in this custom nitch field of slope glazing, has vested hours and hours into the development and manufacturing of the Gramercy Park project.  He is setting back for a few minutes and savoring into a comfort zone knowing that all went as planned, this day he will never forget. Even though it’s blistering cold on the roof, the excitement of the day gave warmth to all that were a part.

Score… was the word of the morning from Kevin. After de-thawing in a hot shower all night Kevin was excited that he made it back to the roof at 7am the second day of install. In pain and prepared for another day of biting weather, he felt that he beat the odds and made it. Oh yes, the stories go on….

Cliff, the Hotel Manager offers a private tour to one of his friends as the system is being installed. Proud of everyone’s efforts, Cliff and his staff not only provided Roll-A-Cover with 5 star hospitality, but also friendships that will last forever. Thank you Cliff for a job well done.

There were many, many people that were important to this project and their affiliation with Shawmut Construction as valuable leaders with the site preparation process.  Also the organization of the weekend added tremendous amount of support to the entire process.

Bruce continues to prepare the final components for installation.  His efforts on this project were ready, willing, and able at all times. From being apart of the ground support team to assisting the fabrication team on the roof, he was always there. Kudos’ to Bruce.

As the day turns to night the crane puts the final touches on the roof…

and the sky starts to pause with the staff calling it a day…

Doug with Dave and Michael now can say that we beat the weather and achieved our goal. It was a weekend to remember...

With the Staff and owners of the Ian Schrager Group and the Hotel management as well with Michael Morris, president of Roll-A-Cover, the excitement of the install was just the beginning now the real work is about to start. The finishing touches of the roof top garden which will make the Gramercy a model for all high-rises

From all of us at Roll-A-Cover, Intl, we would like to thank Ian Schrager himself and the entire team at the Gramercy for providing us with this tremendous opportunity in offering once again to one of the most respected hotels in New York City our products and services. Your respect for my staff and company during this entire process will ever go unspoken. With years of success on your new roof top venue; we wish you the best from all of us.