Commercial Re-Roofing

Commercial Re-Roofing in Austin, TX

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  Commercial Re-Roofing for commercial buildings across Austin.

  TPO is the most-installed commercial single-ply membrane in Austin commercial work. We install 60-mil and 80-mil systems against manufacturer-spec details, suited to Central Texas heat loads, with 20-year no-dollar-limit warranty paths.

  Thermoplastic polyolefin (TPO) became the dominant commercial single-ply membrane in Austin over the last two decades for a straightforward reason: a properly installed white TPO roof reflects 80–90% of incident solar radiation, which matters on a flat commercial roof in a city that regularly logs 90-plus days above 100°F ambient temperature. On a dark or aged membrane, surface temperature can exceed 165°F on a peak Austin summer afternoon. On a properly installed 60-mil white TPO, that surface temperature drops to the low 100s — a material reduction in cooling load for any building without heavy rooftop shade.

  TPO is also heat-weldable at the seams, which produces mechanically superior lap joints compared to adhesive-bonded or tape-sealed membranes. When installed at correct weld temperatures and speeds — which vary by membrane brand and ambient temperature — a TPO seam is stronger than the base membrane. When installed incorrectly, the seams are the first failure point. We calibrate weld parameters to current ambient conditions, not to a fixed setting.

  Austin's hail history matters for TPO membrane selection. The June 2024 storm dropped quarter-size hail across Round Rock and Pflugerville. The November 2022 storm affected north Travis County. We specify 80-mil TPO for buildings in hail-exposed locations or those with known limitations on maintenance access — the additional membrane thickness extends impact resistance meaningfully. For buildings with frequent foot-traffic or rooftop mechanical work, we add walk pads at access routes.

  How We Install TPO on Austin Commercial Buildings

  Substrate preparation: The existing deck — typically steel or concrete for commercial applications — gets inspected for fastener pullout resistance before we anchor the insulation. Steel decks corroded below structural spec get documented and flagged for the owner; we do not install over compromised deck.

  Insulation: Polyiso board in a single or double layer depending on required R-value, mechanically fastened to deck at pattern density calculated for wind-uplift zone. A HD polyiso or gypsum cover board over the primary layer gives the TPO membrane a smooth substrate and reduces thermal bridging at fastener locations.

  Membrane: 60-mil for standard commercial applications; 80-mil for hail-exposed or high-traffic roofs. Rolls are positioned with factory-selvedge edges aligned for overlap, then hot-air welded at 1.5-inch minimum weld width. Weld quality is verified by probe test every 100 linear feet and by tensile pull test on sample welds at start of each day and after any break in production. We do not field-test only; seam width and weld temperature are logged throughout.

  Flashing: All penetrations, curbs, edges, and parapets get TPO-compatible flashing membrane, either pre-formed or cut from roll, welded to the field membrane. Parapet coping cap is aluminum or galvalume; exposed coping joints are sealed with compatible TPO sealant, not generic caulk.

  TPO Warranty Paths on Austin Projects

  Standard commercial TPO warranties run 10, 15, or 20 years from most major manufacturers. The 20-year NDL (no-dollar-limit) warranty covers material and labor cost to repair or replace any warranted failure — it is the benchmark for commercial property owners who want to transfer the roof liability to the manufacturer for the warranty period.

  NDL warranty qualification requires the manufacturer's field inspector to walk the completed roof and sign off on details. Most national TPO manufacturers have regional reps covering Central Texas. We schedule the inspection as part of the closeout sequence — the warranty document does not issue until the field inspection passes.

  Warranty maintenance is required by every major manufacturer to keep the warranty in force. Typically: one annual inspection by the contractor with a written condition report submitted to the manufacturer, caulk and sealant renewal at penetrations and terminations on the inspection schedule, and prompt repair of any membrane puncture or mechanical damage within the coverage period. We offer maintenance contracts structured to each manufacturer's requirement — not a generic annual visit.

  TPO Recover vs. Full Replacement in Austin

  If the existing roof system has dry insulation (confirmed by moisture core sampling) and a structurally sound deck, recovering over the existing system with new TPO can extend asset life 15 to 20 years at roughly half the cost of full replacement. The recover eliminates tear-off and disposal costs, which matter more on larger Austin roofs where disposal logistics (and the city's landfill tipping fees) add up.

  We do not recover over wet insulation. Wet insulation trapped under a new membrane will continue to degrade the deck, void the new membrane warranty, and produce premature failure. If core sampling shows saturation above 25% of the sampled area, full replacement is the correct scope. Between 10% and 25% wet, we often do targeted insulation replacement in wet zones before recovering the rest.

  Austin's limestone substrate can complicate drain relocation if a recover requires changing slope. We document existing drain locations and ponding patterns in the pre-scope walk and design the recover package around what the drain layout can support — not around a theoretical ideal slope.

  How does Austin's heat affect TPO weld quality?

  Heat-welding TPO in Austin's summer ambient temperatures (95–105°F) requires adjusting weld speed and air temperature settings relative to spring or fall installation. We calibrate daily at start of production and after any extended break. Crews do not run standard cool-weather settings in August — the substrate temperature affects how the membrane flows at the weld, and incorrect settings produce seams that probe-test clean but delaminate under thermal cycling.

  Is 60-mil or 80-mil TPO better for Central Texas?

  60-mil is standard for most Austin commercial applications. 80-mil is worth the additional cost per square for roofs in hail-exposed locations (north Travis County, Williamson County, and Pflugerville/Round Rock have documented hail frequency above the Austin MSA average), for roofs with regular foot traffic or mechanical maintenance access, or for buildings where management turnover makes maintenance consistency uncertain. The 20-mil difference in thickness adds meaningful impact resistance with no change in installation method.

  Can TPO be installed over an existing EPDM or BUR roof?

  In many cases, yes — subject to moisture core sampling confirming dry insulation and a structural review confirming the existing assembly can support the added dead load. The City of Austin Development Services Department requires a permit for recover projects above a certain scope threshold; we pull the permit as part of project set-up. The bigger constraint is often drain elevation: if the existing assembly is already at or near parapet height, an additional insulation-plus-membrane layer may exceed the drains, requiring drain riser modification.

  Get a TPO scope for your Austin commercial building.

  We will walk the roof, sample cores if the recover-vs-replace decision requires it, and provide a written specification you can use for comparison or direct award.

  Commercial Re-Roofing in Austin, TX begins with a structural load check. Before any tear-off is priced, the building's roof deck capacity must be verified against the weight of the proposed new assembly — new insulation, cover board, membrane, ballast if applicable, and any required drainage improvements. For commercial re-roofing in Austin, the code also controls how many membrane layers can remain on the deck: most jurisdictions follow the two-layer maximum specified in the International Building Code, which means full tear-off may be required even when the top membrane looks serviceable.

  Insulation is the largest cost driver in commercial re-roofing after tear-off labor. Energy codes in TX — whether Title 24, ASHRAE 90.1, or a local supplement — set minimum R-value targets for roof assemblies above conditioned space. A commercial re-roofing project that does not meet the current energy code may require additional insulation thickness to obtain a permit, which changes the scope, the deck load, and the tapered insulation design around drains. Commercial Roofing works through those calculations before presenting a commercial re-roofing budget so the number in the estimate reflects the actual permitted scope.

  Permit documentation for commercial re-roofing in Austin typically requires product data sheets, a roof plan or sketch showing drainage and slopes, a disposal plan for tear-off material, and sometimes a structural engineer review letter when the new assembly is heavier than the existing one. We assemble that documentation package and coordinate with the building department on the inspection schedule so the commercial re-roofing project closes without a certificate-of-occupancy hold.

  Warranty implications matter for commercial re-roofing decisions. A roof manufacturer will not extend a new system warranty over a tear-off site with an unaddressed deck repair or compromised substrate. We document deck conditions found during tear-off, provide photographic evidence of substrate quality, and give ownership the information needed to decide whether manufacturer warranty coverage is worth the additional substrate repair cost. Call or email to schedule a commercial re-roofing assessment in Austin.

  Widespread wet insulation, a second membrane layer already present, deck deterioration, repeated failed repairs, and energy code compliance gaps on a permit-requiring scope all push toward full re-roofing.

  ASHRAE 90.1 or state-specific energy codes set minimum insulation R-values that may require added insulation thickness beyond what the existing assembly provides, increasing both cost and structural load.

  Product data sheets, a roof plan or sketch, a disposal plan, sometimes a structural engineer review, and contractor licensing documentation. We assemble the permit package and coordinate the inspection schedule.

  Membrane layer count, deck condition found during inspection, moisture scan results, and the code-required maximum layer count all determine whether full tear-off or partial removal is required.

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