Garanco, Inc., of Pilot Mountain, N.C. renovated McIntyre’s manufacturing plant in three phases, spanning just over three years. The roofing materials included 136 skylights, provided by Roof Curb Systems (RCS), which are designed to help McIntyre keep a tight rein on electrical and energy costs.

“They love the natural light of the skylights,” says Project Manager for Garanco, Adam Stanley. “The natural light, paired with a daylight harvesting lighting system, will automatically dim the lights when necessary. It’s going save the company a lot of money on power as well.”

Cost Control

While every manufacturer is different, it is essential to control utility costs, which can represent upwards of 30 percent of the annual budget in a manufacturing facility. Water, electricity and sewer are the primary utility costs.

Electricity is frequently the most prominent utility cost. The industrial sector accounts for approximately 33 percent of all energy costs in the United States, and 77 percent of all industrial electricity goes to manufacturing.

North Carolina has one of the lowest commercial rates for electricity in the United States – 10.92 cents per kWh – and is one of the reasons the Tar Heel State is a favorite of manufacturers. It ranks 8^th in the nation for its manufacturing contribution to the national Gross Domestic Product and was named the best state for manufacturing in 2024 by Site Selection Group.

Three-Phase Project

The massive renovation at McIntyre kicked off with the installation of 44 skylights, measuring 30-inches by 120-inches, on a 65,000-square-foot pre-engineered metal building. The roof also included six smoke vents that were equipped with skylights. The smoke vents deploy automatically upon the melting of a fusible link and help firefighters bring a blaze under control by removing smoke, heat and gases from a burning building.

The second phase covered 130,000 square feet and included 62 skylights, also 30 x 120, and the third phase included a 90,000 square foot new construction building that featured 30 skylights. RCS also provided roof curbs for the rooftop process piping on the final phase, and additional HVAC equipment curbs during the project’s earlier phases.

System Integration

RCS, of Trenton, Ga. provided traditional curb mounted skylights from VELUX for the project. The process for selecting, installing and integrating the skylights with roofing materials was anything but traditional.

With its “total systems approach,” RCS seeks to integrate high-performance curb mounted skylights with the entire range of roofing materials into a leak-free, thermally efficient package that delivers long-term performance. “There is no universal roof curb for metal roofing integration,” says RCS’ Vice President of Business Development, Clifton Reasor. “The attributes that are going to drive the decision hinge on the roof panel type and manufacturer.”

The McIntyre project posed several complexities. Each building, for instance, had different metal roofing panels. In a standing seam roof panel, RCS developed a curb sub framing system to ensure no gaps exist between the panel and the secondary framing members of the structure. In a screw down roof, there is no gap between the framing and the panel, but it is especially crucial that the curb sub-framing provides a backer for all of the curb flange to roof panel connections. RCSs’ specifically designed curb sub-framing systems are critical to ensure weather-tightness and load transference.

The primary concern with skylights is leaks. RCS takes exacting measures – offering customized solutions – to ensure successful system integration that eliminates leaks but also provides the proper level of daylighting, thermal efficiency and consistent appearance throughout the 33-acre development.

“Consistency is important,” Reasor says. “We were able to take different roofing types and give them a consistent, finished product, especially in terms of interior daylighting. We took the dimensions of each building and provided a layout that yielded consistent overlapping natural light that was paired with the right skylight size.”

Seeing the Light

Skylights optimize daylight, energy efficiency, occupant comfort and visual interest in new and renovated buildings. Whether one or many, fixed or operable, long-spanning or short-spanning, skylights are seen in every type of commercial facility.

While reducing electrical lighting demands, research shows skylights also benefit occupant health and wellness, increase employee accuracy and productivity, improve student test scores and faster patient recovery times.

Skylights can be installed in a wide range of commercial projects – airports, sports venues, hospital lobbies, and shopping malls, for example – but there also critical variables that must be considered.

Glazing choices, framing materials and thermal performance are all choices that require careful selection.

“From a facility management perspective, natural daylighting contributes to lower electricity bills and reduced HVAC loads when designed correctly,” Reasor says. “However, achieving these benefits depends on strategic planning and attention to key performance metrics such as Solar Heat Gain Coefficient, U-Factor and Visible Light Transmittance. Skylights must also meet building energy code requirements.”

HVAC Curbs, Too

RCS also provided curb systems for McIntyre’s HVAC systems, allowing for weather tightness throughout the entire roofing structure. The curbs provide a stable and level base for rooftop equipment, preventing damage to the roof and ensuring proper operation. The raised frame with integrated cricket ensures water can drain from the unit and roofing material, preventing leaks and potential damage to the building.

“We were extremely happy with RCS, and they helped us expedite the overall project,” Stanley says. “The quality of the construction is part of the reason it went as quickly as it did. The customer saw the finished product and it incentivized them to fast track the overall schedule for growth.”

The daylighting components and customized system from RCS will do more than help McIntyre contain its energy costs. It delivers a dependable, weather-tight and energy-efficient assembly that will help the manufacturer remain at the forefront of its business with an enhanced daylit environment for workers.

“We’re the only ones in the industry that provide that level of detail,” Reasor says. “A custom proposal was the most efficient and effective solution for this project. In phase one, it started out as a building restoration project. It evolved from there, and the developer and tenant liked the finished product. The coordination efforts on the front-end of this project led to a successful multi-phased solution that showcases the adaptability and effectiveness of RCS’ processes and products which is something we are proud of.”