The Problem

The existing built up roofing system had exceed the limit of its servicable life and was on the verge of full blown failure. Numerous attempts at spot and area repair had no lasting effect on long-term performance. Recurring and new leaks were causing problems with the manufacturing process in the plant. Re-roofing was the only feasible approach to return the building to a water-tight condition.

The Solution

An infared scan was performed to locate wet insulation. These wet areas were marked and core tested to verify moisture content.

Loose stone was vacuumed from the roof surface. Areas of wet insulation were removed and replaced with dry insulation. These areas were then sealed with hot asphalt and roofing felts and tied back in to the existing roof.

The roof surface was then flooded with hot asphalt, and a layer of polyisocyanurate insulation board was embedded in the hot asphalt.

A white TPO membrane was then fully adhered to the new insulation layer. All seams were welded with hot air welders (no adhesives or tapes). New fully adhered wall, curb and projection flashings were installed and secured with new aluminium counterflasings, termination bar or copings as applicable. The new TPO roof was effectively separated from and tied into and existing built up roof on one side and an existing EPDM roof on another side.

TPO coated metal was used to fabricate new pitch pockets for a number of roof top penetrations. These pitch pockets were then filled with a grout mix and topped off with a non-shrink pourable rubber sealer. Protective TPO walk tread mats were heat welded to the surface around mechanical units.

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