Overview
HydroQual and the New York City Department of Environmental Protection implemented a custom blue roof infrastructure project to manage urban stormwater runoff. By utilizing specially fabricated anodized aluminum detention trays manufactured by Fat Daddio’s, the project successfully reduced roof runoff by 32 percent during heavy rainfall. This initiative helped divert up to 750 gallons of stormwater per storm, preventing untreated wastewater from entering the East River and validating a scalable model for citywide environmental infrastructure.
Brand Story
New York City relies on its surrounding waterways for commerce, recreation, and ecological health. However, protecting these waters requires innovative approaches to urban engineering. The New York City Department of Environmental Protection established the Green Infrastructure Program to explore and deploy systems that manage stormwater before it reaches the sewer network.
In 2012, this program led to the largest custom blue-green infrastructure project in the city at the time. HydroQual, a prominent environmental engineering firm, partnered with the city to design a solution for the Bronx River Houses. This location served as a showcase site for stormwater innovation. The Osborne Association also played a key role in the initiative, working to reduce the amount of pollution discharged into the East River. To bring this vision to life, the project required a manufacturing partner capable of producing precise, durable, and weather-resistant materials. Fat Daddio’s, a brand globally recognized for high-quality bakeware, stepped in as a vital partner in sustainable urban infrastructure, applying decades of United States aluminum fabrication expertise to a critical municipal challenge.
The Challenge
The aging sewer infrastructure of New York City was severely overwhelmed during storm events. Because the city uses a combined sewer system, heavy rainfall mixes with wastewater. When stormwater exceeds the capacity of the sewer system, this combination of storm runoff and wastewater is discharged directly into local waterways like the East River. These overflow events caused billions of gallons of untreated wastewater to pollute the harbor, creating the top water quality challenge for the region.
To address this massive environmental pain point, the city set aggressive targets. Officials aimed to manage stormwater on 1.5 percent of impervious surfaces by 2015, with a broader goal of expanding that footprint to 10 percent by 2030. They needed a scalable, low-cost solution to delay and reduce the runoff entering the sewer system.
However, traditional green roofs presented challenges regarding weight, maintenance, and structural requirements for older buildings. The engineering team needed a custom component that was highly durable but lightweight enough for standard flat roofs. The solution had to be cost-effective for wide deployment, flat and modular for easy installation, and engineered with specific drainage openings. Furthermore, the material had to be highly resistant to corrosion and the extreme weather fluctuations typical of New York City.
The Solution
Fat Daddio’s stepped in, operating not as a kitchenware supplier, but as a precision aluminum fabricator. The project team designed and implemented an innovative blue roof system utilizing our manufacturing capabilities. We fabricated 180 custom anodized aluminum trays specifically engineered to hold, slow, and drain rooftop rainwater safely.
Each tray measures 2 feet by 2 feet and features a 20-inch square pan design. The team integrated a customized hole pattern into the base of the pans to ensure a slower, controlled draining process atop buildings situated along the East River. To keep the modular system secure, approximately 2 inches of crushed stone ballast, along with rock and sediment, was added to each tray.
This system controls stormwater runoff by combining blue detention trays that systematically slow the flow of water into the sewer system. By utilizing anodized aluminum, the trays are highly resistant to corrosion and capable of withstanding year-round exposure to the elements. Crucially, this modular aluminum system weighs 50 percent less than a total green roof installation, making it lightweight enough for widespread rooftop use while remaining structurally sound. Fat Daddio’s delivered all components on time and within budget, enabling the New York City Department of Environmental Protection to install the trays on a flat roof at the Bronx River Houses to rigorously test performance during active storms.
“We’re known for precision bakeware,” said Fat Daddio’s Vice President, Greg Skipper. “This project demonstrates that our custom fabrication capabilities extend far beyond the kitchen.”
Results
The pilot installation at the Bronx River Houses delivered measurable, highly scalable impact for the Green Infrastructure Program. A six-month follow-up assessment demonstrated overwhelmingly positive results, and independent analysis from BuildingGreen validated the engineering approach.
The custom anodized aluminum tray system successfully reduced roof runoff by about 32 percent. During each storm event, the trays captured approximately 750 gallons of rainwater, significantly delaying its entry into the sewer system. When combined with complementary rain gardens and advanced piping systems on the property, the Bronx River Houses site now manages over 1 million gallons of stormwater per year.
The project successfully reduced both peak runoff rates and total stormwater volume. Furthermore, the pilot validated the performance of modular tray systems against other blue roof technologies. The Fat Daddio’s trays outperformed alternative systems during high-intensity storms, specifically excelling in water retention, controlled drainage, and long-term durability.
Looking Ahead
This collaboration highlights the remarkable capabilities of manufacturers willing to apply their core expertise to entirely new industries. By proving that blue roof infrastructure can be lightweight, durable, and highly effective, the city now possesses a validated model to scale across other flat-roof buildings to meet its 2030 capture targets. Fat Daddio’s will continue to serve as a reliable United States aluminum fabrication partner, building engineered, affordable solutions. Whether the application involves culinary arts or complex municipal cityscapes, our aluminum solutions are built to last.
