Residential Flat Roof Replacement with WeatherBond PVC — Englewood, CO

Project Overview

• Location: Englewood, CO (Greenwood Village area)
• Building Type: Residential single-family home with a flat roof section adjoining a stone-coated steel sloped roof
• Size: Approximately 600 sq ft
• Roofing System: WeatherBond 60-mil PVC over ¼” DensDeck and 2.6” Versico polyiso
• Duration: September 2026
• Completed: September 2026
• Manufacturer: WeatherBond (membrane), Versico (insulation), Georgia-Pacific (DensDeck)
• Warranty: WeatherBond lifetime material warranty

Roof Condition

A homeowner in the Englewood / Greenwood Village area had a roughly 600 sq ft flat roof section on an otherwise stone-coated steel home. The flat area had been coated with polyurea years earlier and the coating was failing, with water working its way in where the flat roof met the sloped steel. Rhino Roofing LLC laid out three options: re-coat the existing surface with silicone (contingent on a moisture test of the deck), replace with Versico 60-mil TPO, or replace with WeatherBond 60-mil PVC carrying a lifetime material warranty. The homeowner chose the PVC.

• Polyurea coating chalked, cracked, and lost adhesion
• No insulation or fire-rated board meeting current code
• Flat membrane did not extend far enough up the slope at the steel transition
• Wind-driven rain and snowmelt getting behind the stone-coated steel panels onto the deck

Evaluation & Approach

The polyurea coating had chalked, cracked, and lost adhesion in areas, and the flat roof had no insulation or fire-rated board that would meet current code on a re-roof. The weakest point was the transition where the flat membrane terminated against the stone-coated steel panels — the original installer had not run the flat roofing far enough up the slope, so wind-driven rain and snowmelt got behind the steel and onto the deck.

Why This Approach

• WeatherBond PVC carries a lifetime material warranty
• Superior seam weld strength compared to TPO
• Excellent resistance to ponding water on a low-slope residential section
• On a small roof the membrane is a fraction of the cost — PVC was only a few hundred dollars more than TPO
• Running the membrane 16” up under the steel creates a proper shingled, gravity-driven water path
• Class A fire rating with DensDeck meets current re-roof code requirements

Scope of Work

1. Tear-Off and Deck Inspection: Removed all layers of existing flat roofing and insulation down to the wood deck and inspected for rot.
2. Insulation Installation: Installed 2.6” Versico VersiCore MP-H polyiso insulation (R-15 LTTR) to meet current energy code.
3. DensDeck Roof Board: Installed ¼” DensDeck gypsum roof board over the insulation for Class A fire rating, impact resistance, and a solid bonding substrate.
4. PVC Membrane Installation: Installed WeatherBond 60-mil polyester-reinforced PVC membrane with hot-air-welded seams.
5. Stone-Coated Steel Transition: Removed the two lowest rows of stone-coated steel panels, ran the PVC a minimum of 16” up the slope beneath them, then reinstalled the steel over the membrane for a shingled, weathertight transition.
6. Edge Metal and Permit: Installed 2” x 4” pre-painted metal drip edge at the gutter perimeter to terminate the membrane and direct water into the gutters. Pulled the permit and completed inspection.

Result

Warranty: WeatherBond lifetime material warranty

• Lifetime Material Warranty: WeatherBond 60-mil PVC membrane backed by a lifetime material warranty
• Code-Compliant Assembly: Fully insulated with polyiso (R-15 LTTR) and Class A fire-rated DensDeck board
• Proper Steel Transition: PVC runs 16” up under the stone-coated steel panels for a shingled, gravity-driven water path
• Reflective White Surface: Bright white PVC reflects heat off a roof section directly over living space