USE IT OR LOSE IT—RE-ROOF OR

RE-COVER OF EXISTING ROOF SYSTEMS

AIA course #BE091919 (live webinar) 1 AIA LU/HSW; 1 IIBEC CEH; 0.1 IACET CEU*
AIA course #BE091919D (on-demand webinar) *BNP Media is authorized by the IACET to offer 0.1 CEU for this program
 OBJECTIVES

1. Evaluate an existing roof to determine long-term solutions: re-cover,

replacement or coating.
2. Explain the effects a re-cover or replacement decision will have on
your existing system.
3. Explain requirements to meet building code and manufacturers’
requirements.
4. Compare different membrane and insulation product types for
advantages and disadvantages.
 DEFINITIONS
• 2015 IBC – CHAPTER 2
– Re-roofing: The process of re-covering or replacing an existing roof
covering. See “Roof re-cover” and “Roof replacement.”

– Roof re-cover: The process of installing an additional roof covering over a

prepared existing roof covering without removing the existing roof covering.

– Roof replacement: The process of removing the existing roof covering,

repairing any damaged substrate and installing a new roof covering.

• Owner/Tenant and Facility
Department
– Preferred Contractors
– In-house Project Management
• Roofing Consultant
– Design Expert
– Inspection and Quality Control
– Project Management
STAKEHOLDERS
• Architects and Engineers
– Drawings and Specifications
– Designer of Record
• Manufacturers
– Design Assistance
– Preferred Contractors
– System Requirements
• Contractors
– Local Knowledge / Cost Estimates
– Scope of Work Including Additional Trades
– Initial Inspection
 EXISTING ROOF EVALUATION
History of Roofing System
What type of roof?
Existing documentation available?
Under warranty?
How many roofs?
Any history of leaks?
Can the building structurally support an
additional roof system and material?
 EXISTING ROOF EVALUATION
Leak Analysis
Is the roof now leaking? For how long?
Where is the water entering the building?
Does water enter the building with every rain, or only during a driving rain?
Does water enter the building as soon as it starts raining, or significantly later?
Does water stop entering the building as soon as it stops raining, or continue to leak for
hours/days?
Does water enter the building during clear dry weather or only during very cold weather
(condensation)?
Has anyone attempted to repair the roof, and if so, do you know what has been done? Were the
past repairs successful?
 BUILDING INSPECTION
Information Documentation Exterior Inspection
Roof plan Walls bowing/cracks
Photographs Efflorescence/ water stains/moss algae
Trees, branches
Interior Inspection Fasteners heads showing (backout)
Rust/water stains
Deck type and span
Evidence of fasteners
Deflection/cracks
 ROOF INSPECTION
Perimeter of Roof
• First point of inspection as most leaks
occur in this area (60%)
• Check counterflashing, edge metal,
gutters, cracks in walls
• Check base flashing for tenting or
wrinkling
• Check attachment at perimeter nailers
• Check securement of nailers to deck
 ROOF INSPECTION
Field of Roof
Seams
Deck deflection/improper slope
Ponding water areas
Vegetation growth
Granule loss
Equipment Installations
Debris/screws
Aging
Deterioration, cracks
Blisters (vapor)
Splits (shrinkage, movement)
Drains
 ROOF CUTS AND TESTING
Core Cuts: 1 per SQ (3″ dia.)
System discovery
Deck condition
Venting
Nondestructive Testing
Moisture scan
Thermal imaging
Nuclear backscatter
Pull Tests
Deck condition/gauge/age
 BUILDING MODIFICATIONS
Occupant’s needs changing?
Modify roof system
Adding Components
Additional insulation
New HVAC/Solar
Expansion joints
Additional drainage
Tapered insulation
ROOF RE-COVER

ADVANTAGES
• Additional insulation is not
required
• Save on disposal and
insulation replacement cost
• Limits building interior’s
exposure during renovation
• Defer the cost of removal
RE-COVER
DISADVANTAGES
• Adds additional weight
– Review by engineer
• Unable to inspect structural deck
• Existing material deterioration
– Can the service life perform for another
20 years?
• Less energy-efficient roof system
 DECK CONSIDERATIONS
• Steel • LWIC – an above deck component
– Deck integrity (not a structural deck)
• Structural concrete – Fasten to metal deck below
– Non-nailable
– Typically adhere
• Wood
• Tectum - CWF
• Gypsum

ROOFING RE-COVER REQUIREMENTS
Section 1511.1 General: Exceptions
• 1. Roof replacement or re-cover of existing low-
slope roof coverings shall not be required to
meet the minimum design slope
requirement of one-quarter unit vertical in 12
units horizontal (2-percent slope) in Section
1507 for roofs that provide positive roof
drainage.
CODE REQUIREMENTS
• 2. Re-covering or replacing an existing roof
covering shall not be required to meet the
requirement for secondary (emergency
overflow) drains or scuppers in Section
1503.4 for roofs that provide for positive roof
drainage. For the purposes of this exception,
existing secondary drainage or scupper
systems required in accordance with this code
shall not be removed unless they are replaced
by secondary drains or scuppers designed and
installed in accordance with Section 1503.4
 CODE REQUIREMENTS
• Two roof maximum • Additional insulation not always
• Replace water soaked and required = roof deck not exposed
deteriorated materials • Overflow drains: match existing
• Cool roof requirement
• Fire rating – Exterior UL A, B, C,
maintain existing
• Re-cover slope:
– Positive drainage
– Ponding area repair
 LOW-SLOPE ROOF SYSTEMS
• Low=Slope = less than 2″ per foot (2:12)
• Standards Entities
– NRCA: Roof systems, details, methods, quality control, etc.
– SMACNA: Sheet metal details, edge metal, expansion joints
– ANSI / SPRI: Edge metal wind resistance
– ASCE 7- (5, 10, 16): Wind uplift calculations
– UL: Fire resistance (interior P-ratings, exterior A,B,C ratings)
– FM Global: Insurance company – wind, fire & hail resistance of roofs; testing to destruction
– FBC: Florida Building Code (Florida Product Approvals, HVHZ) assemblytesting
– Miami-Dade County: Notice of Approval (NOA) assemblytesting
– Texas Department of Insurance (TDI): assembly testing
– IBC: International Building Code
– CRRC: Cool Roof Rating Council
– ENERGY STAR®
 PREPARATION/SEPARATION
Material Compatibility:
Separation layer
• Insulation board
• Re-cover board
• Slip sheet/fleece Asphalt:
remove loose granules Coal
tar: install base sheet Gravel:
remove loose gravel
Surface Preparation:
Sweeping/blowing/washing
Disabling Membrane
• Cutting to vent water vapor
• 3″ cores per SQ
• 10ʹ by 10ʹ grid
Remove membrane
• Fastened/adhered
Existing ballast
• Remove or reuse
 RE-COVER MEMBRANE OPTIONS
• Multi-ply Membranes • Single-Ply Membranes
– SBS – TPO smooth or fleece back
– APP – PVC smooth or fleece back
– EPDM
• Coatings
– Silicone
– Urethane
– Acrylic
 RE-COVER INSTALLATION
Mechanically attached membrane
Attach separation layer
Fasten membrane

Fastened/Adhered
Fasten cover board, adhere membrane

Adhered/Adhered
Bonded pull test
Adhere separation layer/membrane
 FLEECE BACKED SINGLE-PLY MEMBRANES
TPO and PVC adhered with urethane
adhesive (foam) or asphalt
Existing granulated cap sheet
20 warranty available

Fleece backed (FB) membrane over

existing asphalt (hybrid system)
Enhanced chemical resistance
Increased durability
 SMOOTH BACKED SINGLE-PLY
EPDM, PVC, and TPO
Mechanically fastened or adhered
Slip sheet (MF only)
Insulation or cover board
25 year warranty available
 MULTI-PLY SYSTEM
SBS or APP – Two Ply System
Fasten base ply and torch/adhere cap ply, no insulation required
Fasten insulation/cover board, torch or adhere membranes
20 year warranty available
ROOF REPLACEMENT AND
PARTIAL REPLACEMENT

Roof replacement: The process
of removing the existing roof
covering, repairing any damaged
substrate and installing a new roof
covering.
ROOF REPLACEMENT
• Project conditions or owner indicate
a new roof
– Extremely damaged existing roof
– Multiple systems already present
– Upgrade existing system
• Select membrane type
– Multiply or single-ply
– More options available for
installation methods
 ROOF REPLACEMENT
ADVANTAGES DISADVANTAGES
• All new materials • Additional time and possible
• Option to re-cover at later date disruption to occupants
– Logistics
• More efficient roofing system
– R-value • Greater investment
– Reflectivity – Existing roof disposal
– Emissivity – Additional trades – MEP – Disconnect
or adjust existing pipes, equipment,
• Allows for proper structural inspection nailers and curbs
– More material
 NEW ROOF CODE REQUIREMENTS
• Fire rating – Exterior UL A, B,C • Drain requirements
• Wind resistance – uplift pressures – Add secondary drains for
• Meet new energy code for: emergency overflow
– R-value • Slope
– Reflectivity – ¼-inch minimum – 1/8 is not
acceptable per IBC
 PARTIAL REPLACEMENT
• Remove existing membrane to
reuse existing insulation
– Save cost
– Is R-value upgrade required?
– LTTR
• Must add new insulation over
existing insulation as a separator
• LWIC – Lightweight Insulating
Concrete
– Common Solutions
• Adhere
• Nail base
• Venting base sheet
– Moisture concerns/venting
solutions
LIQUID-APPLIED ROOFING
AND COATING SYSTEMS
 COATING CONSIDERATIONS
• Silicone • Cost
• Acrylic • Odor
• PMMA • Installation
• Urethane Resins – One or two component
• Don’t use if:
– Extensive moisture trapped
– Complete granule loss
– Extensive seam failure
 COATING VS MEMBRANE
• Coating without reinforcement is • Thickness: wet vs dry
not considered membrane – 90 mils wet = 45 mils dry
– Polyester helps distribute stress – Water/solvent carriers
• Extend roof life
– Reduce solar heat gain
– Granule adhesion
– Light oil retention
 PREPARATION AND INSTALLATION
• Clean and dry surface
– Spud existing gravel
– Remove loose granules
– Replace flashing/metal
• Options for existing roofs
– Single-Ply
– Multi-ply
– Metal
– Coal tar
– Spray Polyurethane Foam (SPF)
 GUARANTEES AND MAINTENANCE
• Contractor Guarantee • Maintenance: Biannual inspection
– 2 - 5 years – Stored materials
• Manufacturer Guarantee – New equipment
– 10 - 30 years – Repairs
• Material guarantee vs System – Ponding areas
guarantee – Drains and gutters
– What is covered? – Blisters
– Building settlement/movement
ROOFING OPTIONS
 BUILT UP ROOFING
Recommended Use:
• Redundant layers of protection
• Proven over time
• Options for finish: gravel or granular cap sheet
(customize)

Not Recommended For Use:

• One layer cannot stand alone. Asphalt is required to
complete the system.
• Always glass reinforced
• More labor intensive
• Asphalt fumes
 SBS
Recommended Use:
• Excellent history of performance in wind and storm areas
• Application methods – torch, hot asphalt, cold applied,
self-adhered
• Broad performance characteristics, polyester, fiberglass,
or combination
• Can be integrated with PVC as A hybrid system
• Long term ownership - data centers, schools, and
government buildings
Not Recommended For Use:
• Chemical exposure to oil or hydrocarbon base materials
• Short term owner – flipping property not cost effective
• Contractor needs to be certified by manufacturer
 APP

Recommended Use:
• Great for high temperature areas
• Cold or torch application
• Higher tear strength with polyester reinforcement
• Ability to match asphalt shingle colors

Not Recommended For Use:

• Not recommended for cold climates
• Limited contractor base – (limited tier 1 contractor
base)
• Less fire protection than SBS
 EPDM

Recommended Use:
• Works well in Northern climate heating days
• Great resistance to cold weather
• Ballasted – wide sheets for warehouse space
• Fast installation, less expensive
• Unsecured flashing may be easier to install

Not Recommended For Use:

• No oils – EPDM swells and changes chemistry
• Prime, tape and apply seams increases installation
time
• White EPDM not recommended – ever
 TPO
Recommended Use:
• High reflectivity
• Big box stores and strip malls
• Flipping properties
• Less expensive solution
• High wind uplift – stiffness and reinforcement good weld
seams (inner ply adhesion)

Not Recommended For Use:

• No oils – airports, processing plants, or kitchens
• Not recommended for ballasted – plasticizer loss
 PVC

Recommended Use:
• Will withstand oil from airports, processing plants,
manufacturing plants and kitchens
• Best to use where roof is exposed to chemicals
• Auto weld seams

Not Recommended For Use:

• No ballast – plasticizer loss
 PMMA

Recommended use:
• Plaza decks, green roofs, difficult access, irregular
roofs, small areas with substantial penetrations
• Occupied buildings: VOC-free (no torch or kettles)
• High value projects: very robust solution with no seams
• Difficult access: easier to load and move than rolls

Not recommended for use:

Price sensitive projects