Buckley Powder Co. — SPF Tear-Off and Metal Roof Recover with Versico TPO, Englewood, CO

Project Overview

• Location: Englewood, CO (Inverness business district, Douglas County)
• Building Type: Industrial warehouse and distribution facility
• Size: Approximately 12,500 sq ft across two roof areas
• Roofing System: Versico VersiWeld 60-mil white TPO, fully adhered, over Versico SecurShield polyiso
• Duration: 6 Weeks
• Client: Buckley Powder Co.
• Completed: August 2026
• Manufacturer: Versico

Roof Condition

Buckley Powder Co.'s warehouse in Englewood's Inverness business district had two different roof systems failing at the same time: a spray polyurethane foam (SPF) roof over the main building and an aging standing-seam metal roof over the adjoining structure. Rhino Roofing LLC had performed an SPF patch and silicone repair on the foam roof the previous fall, but the system was past the point of patching. The biggest problem was the void where the two buildings met: a gap between the metal headwall and the flat roof that had been collecting water and debris for years, with no proper deck, flashing, or drainage.

• Widespread SPF foam degradation, blistering, and moisture infiltration where the coating had worn through
• Metal roof had failing seams and see-through fiberglass skylight panels that leaked
• Void between the two buildings had no proper deck, flashing, or drainage
• Water and debris collecting in the headwall gap for years

Evaluation & Approach

The SPF roof was beyond further patching. A full replacement that brought both the SPF area and the metal area under one Versico 60-mil TPO assembly gave Buckley Powder a single 20-year manufacturer warranty, eliminated the void between the buildings, and kept the warehouse operating throughout.

Why This Approach

• Recovering the metal roof with flute fill and polyiso avoids demolition cost and keeps the building watertight
• Fully adhered TPO over both areas means no exposed fasteners and a smooth reflective surface
• One continuous membrane eliminates the seam between the two buildings
• 20-year Versico Total System warranty covers membrane, insulation, and accessories edge to edge
• Warehouse stayed in full operation for all six weeks
• Reflective white TPO lowers cooling loads on the warehouse

Scope of Work

1. SPF Tear-Off (Area 1): Tore off existing SPF roofing system down to the deck. Installed Versico SecurShield polyiso insulation (R-12.1 LTTR), fully adhered per Versico specifications.
2. TPO Installation (Area 1): Installed Versico VersiWeld 60-mil white TPO, fully adhered with Versico bonding adhesive, all seams heat-welded. Installed and welded clad metal drip edge around the full perimeter (~420 linear feet).
3. Metal Roof Recover (Area 2): Installed EPS flute-fill insulation between the standing seams, then 1½” polyiso over the flute fill. Installed Versico VersiWeld 60-mil white TPO, fully adhered, tying into Area 1 as one continuous membrane.
4. Skylight Replacement: Built six new skylight curbs and installed double-dome skylights in place of the leaking fiberglass panels.
5. Void Rebuild Between Buildings: Installed new decking across the void, lowered the west-side gutter to meet the new roof height, and installed a new 6” seamless gutter with 3” x 4” downspout.

Result

Warranty: Versico 20-Year Total System edge-to-edge warranty

• Unified Roof System: Two failing roofs are now one monolithic, heat-welded TPO system with a single 20-year manufacturer warranty
• Void Permanently Closed: The gap between the buildings that had been leaking for years is permanently closed with proper decking, flashing, and drainage
• New Skylights: Six new double-dome skylights bring daylight into the warehouse without the leaks of the old fiberglass panels
• Zero Downtime: Completed in six weeks on an occupied, operating industrial facility with no interruption to warehouse operations