Replacing a Manufacturing Facility Roof Membrane

Location: Woodbridge, Ontario
Project Size: 140,000 Square Feet
Project Scope: Large-scale membrane replacement utilizing an infrared moisture scan for targeted insulation removal, complete facility-wide insulation overlay for improved R-value, and installation of a mechanically attached 60 mil Carlisle TPO single-ply roofing system.

PROJECT OVERVIEW

Industrial Roofing Services Limited was brought in to address an aging and failing built-up roof (BUR) membrane on a massive 140,000-square-foot manufacturing facility in Woodbridge. When dealing with a roof of this magnitude, a full tear-off down to the structural deck can be incredibly costly and disruptive.

To determine the most efficient and budget-friendly approach for our client, our team initiated the project by conducting a comprehensive infrared moisture scan of the entire roof surface. The scan revealed that the overall quantity of saturated insulation was relatively low. This critical data allowed us to pivot from a full tear-off to a strategic replacing of the roof. By saving the dry, viable insulation and only removing the compromised materials, we were able to deliver a modern, energy-efficient roofing upgrade while providing significant cost savings for the facility’s ownership.

WORK COMPLETED

Our crew executed a precise and large-scale membrane replacement, which included:

• Conducting an initial infrared scan to map out localized areas of wet insulation
• Vacuuming and extracting all existing pea gravel from the roof surface
• Completely removing the failing 4-ply built-up roof membrane
• Excavating and responsibly disposing of the targeted wet insulation identified in the scan
• Installing replacement insulation in the excavated areas to level the system
• Installing a brand new layer of insulation across the entire facility to boost thermal performance
• Mechanically attaching a new 60 mil Carlisle TPO single-ply membrane
• Precision heat-welding all membrane seams to create a unified, watertight barrier

New Roofing System Installed

• Diagnostic Technology: Thermal infrared scanning was utilized prior to construction to scientifically verify the condition of the underlying assembly, preventing unnecessary waste.
• Insulation Upgrade: In addition to replacing the compromised sections, a continuous new layer of insulation was installed, significantly improving the building’s overall R-value and reducing long-term heating and cooling costs.
• Membrane System: 60 mil Carlisle TPO (Thermoplastic Polyolefin). This high-performance single-ply membrane is highly reflective, exceptionally durable, and specifically well-suited for low-traffic roof areas.
• Seam Integration: The TPO membrane was mechanically attached to the deck and all seams were heat-welded, fusing the material together to form an impenetrable shield against water infiltration.

Project Challenges & Solutions

1. Heavy Material Removal at Scale

Before the new system could be installed, years of existing pea gravel needed to be removed from the sprawling roof. We utilized specialized industrial vacuum equipment to efficiently clear the stone from the roof surface, keeping the site clean and preparing a smooth substrate for the membrane replacement without halting the manufacturing work happening inside the building.

PROJECT OUTCOME

By combining advanced diagnostic technology with expert installation, Industrial Roofing Services Limited successfully transformed a failing BUR system into a highly efficient, watertight asset. The decision to perform a membrane replacement rather than a complete tear-off resulted in substantial cost savings for the client while still delivering a massive upgrade in thermal performance (R-value).

The new 60 mil Carlisle TPO system offers a clean, reflective, and low-maintenance finish that is perfectly tailored to the low-traffic demands of the facility. Thanks to it’s brand new flat roof, the manufacturing plant is now fully protected by a modern single-ply system designed to deliver long-term reliability and energy efficiency.

PROJECT GALLARY

BEFORE/DURING

AFTER