Rockley - Houston, TX

Houston, TX – Commercial Roof Using TPO

This 50,000 sq. ft. industrial warehouse’s old modified bitumen roof had begun to fail. 

Too far gone for a restoration, we reviewed a variety of options with the customer and ultimately decided on a TPO solution.

Prior to Flat Roof Tech, the building had a roughly 20-year-old modified bitumen that had begun to fail about 10 years ago. At that time, another contractor coated a good portion of the roof with a white, elastomeric.

“But the roof isn’t white- how did you know?” That’s a great question!

Unlike some of our other projects that only had alligatoring (cracking of black roof cement), this roof had large patches of the roof that were curling and peeling up.

This can happen for a lot of reasons. 1) Most acrylics/elastomerics are junk. 2) Coatings aren’t easy to install correctly. 3) Incorrect coating for the job. Giving the previous roofer the benefit of the doubt- let’s assume they used a reputable product and installed in flawlessly. Elastomeric roof coatings cannot handle ponding water- period. While there were a lot of areas peeling, the worst areas were all discolored and debris laden- sure signs of ponding water.

“Well how do you fix peeling?” Just use a whole lot of roof cement, that will solve everything.

While it might solve the leaks, the roof cement is, at best, a 60 day solution until a real roofer can get out there to fix the problem. As we’ve alluded to before, the roof cement can’t handle UV rays and will begin to crack. The cement dries, adheres nicely to the roof, then pulls the roof apart as it cracks. Where you might have had a single, isolated leak on a failed seam, you now have a massive area that’s ruined and nearly impossible to diagnose where the leak is coming from. That single leak is now several new leaks and much harder to repair. 

No surprise our moisture meter found moisture here.

This roof also had a large bubble under the membrane. We don’t usually see bubbles this large on any roofs other than SPF (Spray Polyurethane Foam). This is generally caused by moisture under the membrane that expands during the phase change from liquid to gas. In the same way massive boils are aren’t an indicator of good health- large blisters are a always a sign of an unhealthy roof.

Leaks don’t always come from the flat part of the roof. Often times old cap metal that is past its service life will fail and allow water to travel into places you’d might not expect, and absolutely never want water to go.

This roof was a little too far gone for a restoration, and TPO was clear solution. After reviewing a variety of options, the customer ultimately decided to go for a fully adhered, 60 mil TPO on 1” ISO. This is a slightly more beefed up option than mechanically fastened TPO, and the rigid ISOboard provides addition R value, as well as leveling out some of the ponding water areas described earlier.

As with all our commercial TPO projects, we included the gold standard- a 20-year NDL (No Dollar Limit) warranty, backed entirely by the manufacturer.

No more leaks. No more anxiety when it rains. We are really good at installing the best roofs.