TPO Roof Replacement with Deck Repair

Project Overview

• Location: Denver, CO
• Building Type: Warehouse
• Size: 1,500 SF
• Roofing System: TPO Membrane
• Duration: 3 Days
• Scope: Full Tear-Off + Deck

Roof Condition

This Denver warehouse presented a situation where the roof system had deteriorated beyond the point of repair or coating. During our inspection, we discovered not only membrane failure but significant deck damage from prolonged water infiltration. The existing roof had multiple leak points that had allowed moisture to penetrate for years, causing structural damage to the deck substrate. This required a complete tear-off down to the structural framing, deck replacement, and installation of a new TPO system.

• Multiple active leak points throughout the roof
• Deck deterioration from prolonged moisture exposure
• Saturated insulation with no remaining R-value
• Structural damage requiring deck replacement
• Failed membrane beyond repair or coating

Evaluation & Approach

The extensive deck damage made this a clear-cut replacement project. Coating or overlay systems require a solid substrate, and this roof had deck sections that needed complete replacement. Our approach was to remove all existing materials, replace damaged deck sections, and install a new fully-warranted TPO system that would provide decades of protection.

Why This Approach

• Complete access to deck for proper repairs
• New TPO system with full manufacturer warranty
• Proper insulation restoration for energy efficiency
• Eliminates all existing moisture problems
• Long-term solution vs. temporary fix

Scope of Work

1. Complete Tear-Off: Removed all existing roofing materials including membrane, insulation, and damaged deck sections down to structural framing.
2. Deck Replacement: Installed new deck substrate over framing to create solid, clean surface for new roof system.
3. Insulation Installation: New polyiso insulation installed to provide proper R-value and thermal protection.
4. TPO Membrane Installation: New TPO membrane fully adhered with heat-welded seams for superior waterproofing.
5. Flashing & Details: All edges, penetrations, and curbs properly flashed with TPO accessories.
6. Final Inspection: Quality verification and documentation for manufacturer warranty.

Result

Warranty: 20-Year NDL

• 20-Year NDL Warranty: Full material and labor coverage from manufacturer
• 25+ Year Expected Life: TPO systems proven in Colorado climate
• New Deck Structure: Solid substrate for decades of performance
• Energy Efficient: Reflective white TPO reduces cooling costs