Commercial TPO Roof Rebuild in North Denver
Project Overview
- Location: North Denver, CO
- Building Type: Single-story concrete block building
- Size: 1,300 sq ft
- Roofing System: Versico 60-mil white TPO, mechanically attached
- Duration: 1 week
- Completed: September 2025
- Manufacturer: Versico
- Warranty: 20-year No Dollar Limit Total Systems Warranty from Versico
Roof Condition
The old gravel-surfaced built-up roof on this North Denver building had split, been patched many times and was leaking into the building. Water had rotted the roof deck, and part of the interior ceiling had already come down. The roof could not be repaired or covered over.
- Gravel-surfaced built-up roof split and patched many times
- Leaks into the building
- Roof deck rotted by water
- Part of the interior ceiling had already come down
Evaluation & Approach
When the deck is rotted, a new membrane over the top only hides the problem. Taking the roof down to the joists let the crew replace every bad board and start from a sound, flat surface. Denver code requires the insulation upgrade on a full replacement, and R-30 cuts heating and cooling load on a block building. Running TPO up and over the walls removes the wall-to-roof joint where the old roof had been splitting.
Why This Approach
- Taking the roof down to the joists let the crew replace every bad board
- New 5/8 inch OSB decking gives the roof a sound, flat surface
- Denver code requires the insulation upgrade on a full replacement
- R-30 cuts heating and cooling load on a block building
- Running TPO up and over the walls removes the wall-to-roof joint where the old roof had been splitting
- 20-year No Dollar Limit Total Systems Warranty from Versico
Scope of Work
- Tear-Off to the Joists: Tore off the existing roof and removed the old deck down to the joists.
- New OSB Deck: Installed new 5/8 inch OSB decking. Removed abandoned roof penetrations and decked over them.
- Insulation: Installed 5.2 inches of flat-stock rigid insulation to meet Denver energy code at LTTR 30.
- TPO Membrane: Mechanically attached Versico 60-mil white TPO and ran it up and over the walls.
- Eave and Drip Edge: Built the eave with 2x4 wood nailers stacked three high along 120 linear feet and finished it with 4x4 metal drip edge.
- Termination Bar: Installed termination bar along 40 linear feet of vertical wall.
- Gutter: Installed 60 linear feet of 5 inch seamless gutter with a downspout.
- Denver Permit: Pulled the Denver roofing permit for the project, and the permit passed.
Result
Warranty: 20-year No Dollar Limit Total Systems Warranty from Versico
- Structurally Sound Roof: Rotted decking removed to the joists and replaced with new 5/8 inch OSB
- R-30 Insulation: 5.2 inches of flat-stock rigid insulation meets Denver energy code at LTTR 30
- Bright White Heat-Welded TPO: Versico 60-mil white TPO run up and over the walls, with new edge metal and gutter
- Passed Denver Permit: Denver roofing permit pulled and passed, with a 20-year No Dollar Limit Total Systems Warranty from Versico