What we do to help

Koch Foods

Commercial Mississippi Roofing Solution

CLIENT: Koch Foods

TYPE: Emergency Roofing Needs

PROJECT LENGTH: 6 Year Partnership

Customer

Koch Foods is one of the largest poultry processors in the United States and they needed a high-quality roofing company that was responsive, reliable, performed good work always, adhered to strict safety guidelines, and most importantly could keep their business running smoothly without interruption. After experiencing major problems on a previous...More

Koch Foods is one of the largest poultry processors in the United States and they needed a high-quality roofing company that was responsive, reliable, performed good work always, adhered to strict safety guidelines, and most importantly could keep their business running smoothly without interruption. After experiencing major problems on a previous roofing project, Koch Foods turned to EC Malone Roofing for help!


Mohamed Basma is a seasoned Project Engineer with Koch Foods covering AL, MS, and parts of GA, and has over 35 years of industry experience. He began his career with Koch Foods over 7 years ago which is around the time that he first learned about Malone Roofing. Mohamed has just moved to the Central, MS area to start his new role as Project Engineer and needed a good local commercial roofer. Mohamed and the Koch Foods team found that Malone's professionalism, experience, safety, and knowledge made them great partners. Since then, Malone Roofing has been a part of the Koch Foods team.

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CHALLENGES

In the past, Mohamed has relied on Malone’s responsiveness when dealing with roofing emergencies. For example, a section of one the Koch Foods plants that he manages caught fire and he immediately called Roman at Malone roofing with a request to get a team on site that same day to make emergency repairs. Malone Roofing dispatched a crew and they arrived on-site later that night to repair the fi...More

In the past, Mohamed has relied on Malone’s responsiveness when dealing with roofing emergencies. For example, a section of one the Koch Foods plants that he manages caught fire and he immediately called Roman at Malone roofing with a request to get a team on site that same day to make emergency repairs. Malone Roofing dispatched a crew and they arrived on-site later that night to repair the fire-damaged areas to get the area watertight. Because of Malone roofing’s reliability and quick response to an urgent matter, Koch Foods contracted Malone roofing for their next reroofing project. It was important that Koch Foods hire the right roofer who could adhere to Koch Foods’ high standards for safety, workmanship, and reliability to ensure there were no interruptions to the plant’s daily operations. Most importantly, communication and response time were both huge factors now for Koch Foods when choosing Malone to do their work! Because Koch Foods is in the business of food processing, expectations for safety, professionalism, and workmanship from contractors that work on-site are much higher than other building types. For starters, food safety and cleanliness are paramount so when roofers perform work they must with absolute certainty be able to identify and properly repair any reported issues (i.e roof leaks). In addition, any areas of ponding water must be addressed. Also, safety and experience are critical because of the different types of piping (i.e refrigeration) running through the roof and other rooftop details. And finally, it is critically important that any work performed does not impact daily business operations in any way during roof repairs or replacements. This is something that Malone Roofing takes very seriously as well—they go above and beyond what is required of them to ensure they can deliver on Koch Foods' needs while keeping their employees safe at all times.

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PROCESS

EC Malone Roofing provided great communication, professionalism, and expertise to address these concerns. They have always been responsive and viewed as being a part of the Koch Foods team in meeting all their needs to ensure the work would be least invasive as possible and the process as smooth as possible for Koch Foods.


Over the years Malone Roof...More

EC Malone Roofing provided great communication, professionalism, and expertise to address these concerns. They have always been responsive and viewed as being a part of the Koch Foods team in meeting all their needs to ensure the work would be least invasive as possible and the process as smooth as possible for Koch Foods.


Over the years Malone Roofing has performed many types of services for Koch Foods including emergency services, roof repairs, and complete roof replacements. No matter how challenging the roofing project is Koch Foods' #1 rule when performing work at their facilities is no interruptions due to the daily operations which means high standards of safety and quality workmanship must be followed at all times. This has always been true when working with Malone Roofing - whether it be their field or office employees. We have always been pleased with the work that is performed by Malone Roofing and look forward to many more years of working together.

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RESULTS

7+ years later Malone Roofing and Koch Foods are still going strong! Over the years Mohamed has had many opportunities to test Malone’s capabilities whether it’s roof repair, preventative maintenance, leak investigations, roof replacements, and especially emergencies. In fact, back in 2019 a tornado ripped through Morton, Mississippi, and struck ...More

7+ years later Malone Roofing and Koch Foods are still going strong! Over the years Mohamed has had many opportunities to test Malone’s capabilities whether it’s roof repair, preventative maintenance, leak investigations, roof replacements, and especially emergencies. In fact, back in 2019 a tornado ripped through Morton, Mississippi, and struck the Koch Foods Chicken Plant. Over the years Malone roofing has had extensive experience dealing with all types of natural disasters whether it’s thunderstorms, hail storms, hurricanes, or tornadoes…for Malone roofing, this was just like any other day so our teams were ready!


The Morton tornado struck the area the weekend of April 18, 2019. Koch Foods immediately contacted Malone Roofing to respond to substantial damage at the plant. A field team of 15 roofers was quickly dispatched and arrived on the scene to find an area that looked like a bomb had gone off. There were many rooftop units (RTU) that had been tossed across the roof, mangled structural decking, multiple membrane punctures, and large gashes in the roof. Within 6 or so hours our roofing crew was able to make temporary emergency repairs to get the building watertight.


The next step in the process was helping Koch Foods navigate the insurance claims process. We assisted Koch Foods with getting properly indemnified. Our team performed a thorough assessment of the plant’s roofs and we identified 12 sections with damage. Because of the varying degrees of damage between all the roof sections, Koch focused their energy on getting the 4 worst sections addressed first.  


Once all temp repairs and the insurance process were completed, we were now green-lighted to mobilize labor and materials for the project. For this section, we reroofed the area with a new modified bitumen roof, and for the blast area and freezer roofs, we went with a single-ply TPO roof. Because of the wind damaged roof deck, hot work equipment, and multiple trip hazards, this project required that our crews proceed with extreme caution and with almost 100% tie-off from start to finish. 


In the end, our team replaced over 10,000 square feet of structural metal decking while also replacing over 25,000 square feet of roofing that housed the picking and evisceration areas. All of this was completed while navigating an incredibly busy roof with tons of pipe penetrations, RTUs, exhaust fans, and other HVAC equipment on the roof. 


The next challenge was the successful completion of the blast area and freezer area roofs. For starters, when our crew did a few core cuts of the roof we found that it was 16 inches thick because there were already 2 roofs present that were saturated with no slope. The old roof’s poor design led to drainage issues which caused ponding water to happen and ultimately led to large sections of the roofing having wet insulation. We completely removed the old roof and installed a new TPO roof with flat and full tapered ISO insulation however due to challenges with access and all of the curbs and penetrations on the roof, our crew was only able to tear off and install about 200 - 300 square feet per day. Not to mention there were coordination efforts with loading and removing materials from the roof. As a company, this was by far one of our most challenging projects and through it all, we never let in one drop of water. The project was substantially completed in July 2020.  


According to Mohamed Basma, the reason they’ve stuck with Malone roofing is that they are always here for us. We can always rely on them to perform top-quality work in a safe and professional manner. The communication between our team is outstanding and we view Malone roofing as part of the Koch Foods team. Mohamed Basma said that “because of our consistently good experience with Malone roofing I would recommend and hire them again without hesitation.” 

When a tornado ripped through Morton, Mississippi in 2019 and struck the Koch Foods Chicken Plant, the Malone Roofing team was ready. The Morton tornado struck the weekend of April 18, 2019. Our team was immediately contacted to respond to substantial damage to the facility. A field crew of 15 roofers was dispatched and arrived to find units that had been ripped and rolled across the roof, pulled up decking, and had multiple holes in the roof. Within 6 hours our crew was able to make temporary emergency repairs to get the building watertight.

We began by assessing the existing condition of the 15-year-old roofing system, which was over 15 years old. Once finished with that project, we used our experience to help Koch Foods efficiently navigate their selection options for a new blast area roof as well as a freezer roof that needed replacement as well. Both roofs were prepped properly and re-roofed with a high-performance TPO product.


Koch Foods has been continuously expanding its operations over the years. This particular location had several structures that needed to be re-roofed and upgraded. The two primary structures were labeled as the “blast area” and the freezer area. The blast area contained metal roofing that was soaking wet, covered in low r-value insulation material, and could only be accessed through small openings. Our team removed the existing metal sheets and installed a higher-performance tapered ISO insulation system on top of what was left behind. Then we began removing all of the low r-value insulation material in both buildings so that those areas could be dried out before we place a new ISO insulation system on those walls prior to installing new exterior metal panels. The project was completed in July 2020.

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Koch Foods - Testimony

          “They were always there for us and have never failed us once.” 

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439 Dory Street

Jackson, MS 39201

Phone: (601) 352-5940

Fax: (601) 352-5944

MS LIC.NO.– 05871-MC

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Phone: (251) 308-2135

Fax: (251) 308-2162

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