ARWP’s Justin Ewart partnered with Architect David Hertz in the roof and waterproofing design and construction of a home comprised of 4.5 million parts of a Boeing 747. The 747 Wing House project is on a 55-acre property in the remote hills of Malibu, CA. Justin Ewart was contacted by Architect David Hertz for is expertise and creativity in roofing and waterproofing. Justin Ewarts final design plans incorporated using the products  of two manufactures, Versico & PolyGlas. The ARWP team designed a Class A Fire Rated roofing system by installing a three-step process of PolyGlass Self-Adhesive membranes applied directly to the existing aluminum, composite, and wood substrates of the recycled wings.

We were able to achieve a Class A Fire Rating with the PolyGlass Self-Adhesive membranes without the use of fasteners or fire retardant sheet barriers. The use of fasteners for the roofing system was not an option as the fasteners would telegraph through the final layer of Versico TPO roofing membrane and be visible from the different viewpoints of the 747 Wing House. The PolyGlass Self-Adhesive membranes have a granular mineral surface, which provides a great point of adhesion substrate for the final layer of membrane, which was to be fully adhered to the PolyGlass membranes. Hertz wanted a roofing membrane to complement the original aluminum and composite substrate of the recycled wings.

The ARWP team provided Hertz with the Versico TPO (Thermoplastic Polyefin) “Grey” roofing membrane as it was the perfect product for the job. We fully adhered the roofing membrane to the PolyGlass membranes with water based VOC bonding adhesive thus eliminating the need for unsightly fasteners. We worked with Hertz to provide a suitable layout of the membrane as to replicate the metal panel simulation of the original aluminum and composite substrate of the recycled wings.

The real challenge was finishing the roofing membrane along the radial and knife-edges of the wings. In working with our sheet metal fabricator, we were able to design a TPO Clad metal as manufactured by Versico Roofing Products in which the membrane was fabricated fused to the aluminum clad metal. The metal was then custom fit to replicate the shapes of the radial and knife-edges of the wings. Our technicians then welded custom non-reinforced membrane between the metal and original installation roof areas.

The field membrane was secured with a 1″ wide aluminum termination metal beneath the custom clad metal perimeter edging thus preventing wind uplift as the 747 wing project sits at the top of a canyon above Point Mugu. The Versico TPO “Grey” membrane was not as reflective as the white membrane but did provide a Solar 747 Boeing jet. There was a reflectance of 46% after the initial installation.

In the end, the Hertz and owner Francine Rehwald were extremely pleased with the care and consideration that the 4myroof team, now Allied Roofing and Waterproofing, Inc., took into implementing and installing the first ever roof of it’s kind to the recycled wings of a 747 Boeing jet.