Commercial Roofing

Ethylene Propylene Diene Terpolymer, EPDM for short, is most common in low slope, commercial roofing. EPDM has a great resistance to hail damage and a significant lifespan. EPDM is covered by manufacturer labor and material warranties, which are not prorated, and cover labor to repair.

Fully adhered systems have a layer of insulation fastened to the roof deck or existing roof with some prep work. This insulation is typically mechanically fastened with screws but can also be attached with an expandable foam adhesive or, in some situations, hot tar. The rubber sheet is then glued to the insulation and walls using a special bonding adhesive.

One advantage of this system is that it allows larger rolls of rubber to be used, creating fewer seams. It also makes it easy to navigate a very “clean” roof area and locate potential leaks. Thicker rubber sheets also allow for longer manufacturer’s warranty lengths. This is most commonly used in the attachment method in Weathercraft’s territory

Ballasted systems use 1-inch diameter smooth river rock to “hold down” the rubber sheet over a layer of insulation on roof decks capable of supporting this system's weight. It is typically installed over metal or concrete decks. As a result, the insulation is loose, and the rubber sheet is laid on it with all the walls and edges glued down.

This type of system is typically the same cost as a fully adhered system with the initial purchase of the river rock. However, a large advantage is the low cost of future re-roofs due to the ability to reuse the insulation and rock. School systems and large government entities use this system to fit their roofing needs into a set budget while keeping their roofs under manufacturers’ warranties.

Mechanically fastened systems use screws and plates to “stitch” down the rubber sheet over a layer of insulation. These systems are typically used in unique situations rarely seen in Weathercraft territories.

Polyvinyl Chloride, or PVC, is the original single-ply roof system in the US. PVC roof systems are resistant to grease and chemicals, reduce urban heat index, help under-insulated systems, and are white reflective giving a better Energy Star rating. PVC systems vary dramatically in quality and characteristics, as there are many different formulations and manufacturing methods used when producing PVC roof membranes. Sarnafil, Fibertite, GAF are the biggest PVC manufacturers in the US. Weathercraft is qualified to handle all three.

Built Up Roofs (BUR) use a base layer of insulation or asphalt-soaked base sheet, then alternating of hot asphalt and felts to create multiple plies, then capped off by a flood coat of asphalt, gravel, or modified cap sheet. An aluminum coating can be used to extend the lifespan of the roof. BUR’s need to be well maintained and require periodic roof inspections and repairs. Weathercraft mostly uses Elevate and United Asphalt Systems. Weathercraft uses better products, especially at the walls, to ensure a longer lifespan of roofs.

Modified Asphalt Roofs consist of thick three-foot-wide sheets of modified bitumen that have been rubberized for increased strength and weatherproof properties. Typically know as Styrene Butadiene Styrene, or SBS for short. These can be used in tandem with BUR systems or as a standalone. SBS sheets are smooth surfaced but granules can be added for extra protection. Weathercraft uses Elevate SBS systems.

Torch Down Modified Roofs const of thick three-foot-wide sheets of modified bitumen that has been “plasticized” for increased strength and weatherproofing. Typically known as Atactic Polypropylene, or APP, systems. Like SBS, it can also be smooth surfaced or granules can be added for extra protection. APP systems are installed using an open flame torch to heat the asphalt on the back of the sheets. Due to the inherent dangers of using open flames on a roof, APP roof systems are only used in specific situations by crews with regional certification.

Standing-seam metal panels have a vertical seam that is “seamed” with some positive force. Sometimes, a hand or robotic seamer tool will roll over the seam after the panels are installed. Sometimes, there is a snap-lock seam that is not reversible. Other situations have a hidden clip that is mechanically fastened within the vertical seam. Standing-seam panels come in a large variety of widths and profiles.

Standing-seam panels are typically ordered to length and are available in numerous colors. The panels have different types of coatings that hold their color. Kynar coating is common on higher-end panels.

An overlapping panel is the most common type of metal panel on the market. There are numerous manufacturers of these styles of panels — all of which use a different name to describe them. The most basic is a corrugated panel, often seen in agriculture. They have a round-like profile that is overlapped at the seams. In addition, metal buildings and residential buildings often use what is referred to as an “R” panel or a ribbed panel. They are more angular and are typically 3-foot-wide panels with a rib every 12 inches.

When replacing the metal panels on a metal roof system is cost-prohibitive, installing a metal-coating system may be the best form of repair. There are numerous coating formulations and systems on the market that are difficult to tell apart as they all look alike (white). There are two reasons to coat a roof system: The first is if the roof leaks. The second is if the original roof panel coating has been damaged by hail.

Spray-foam systems are two-part spray-applied polyurethane foam, which is put directly to an existing roof or deck. This spray foam is then waterproofed with a coating. These systems are extremely susceptible to any size of hail and high winds, and dirt commonly found in the Midwest. Spray-foam roofs are expensive to remove and will need to be re-coated often, depending on the weather and the original thickness of the coating.