Warehouse roofing for large footprints.

Big roofs, tight programs, no room for leaks

Warehouses and distribution centers put more roof over fewer walls than almost any other building. Roof areas of 100,000 to 1,000,000 sq ft are common, and the roof is often the single largest maintenance liability on the balance sheet. A leak over high-bay racking can ruin stock worth more than the repair, and a roof project that blocks docks costs throughput every hour.

Systems that fit

• TPO — the default: light, fast to install over huge areas, reflective and economical. Mechanically attached systems keep cost down; adhered or induction-welded systems perform better in high-wind zones.
• Coatings — for aging metal and membrane roofs that are still dry. On older exposed-fastener metal roofs, a reinforced silicone system seals thousands of fasteners and laps and can add a decade or more without tear-off.
• Structural standing seam — for owners planning to hold the asset for decades, or for retrofits that add slope and insulation over an old flat roof.
• Solar — few buildings offer as much unshaded roof area. A new white membrane with a planned solar layout is the best time to add an array.

Working around operations

We phase the roof into sections that are torn off, dried in and closed the same day, sequenced around dock activity, peak seasons and the areas where stock cannot be moved. Where tear-off happens above product, we use interior protection and — when the risk justifies it — night work. Material staging, crane lifts and truck routes are planned with the facility team so the yard keeps moving.

Details that matter on logistics roofs

• Drainage. Huge flat areas amplify small deflections. Tapered insulation and extra drains remove ponding that shortens membrane life.
• Skylights and smoke vents. Curbs must be flashed properly, and skylights need fall protection screens or guards.
• Insurance requirements. Many large warehouses are insured to FM Global standards that set wind-uplift ratings, attachment patterns and edge details.
• Insulation upgrades. A tear-off triggers current energy-code insulation levels; on conditioned or cold-storage buildings the energy savings are significant.
• Cold storage. Freezer and cooler buildings need vapor control on the warm side and careful detailing to prevent condensation and ice formation within the roof.

Keep it working

Forklifts do not go on the roof, but HVAC techs, sprinkler contractors and solar crews do. Walkway pads, a sign-in rule for roof access and inspections every spring and fall protect the investment — see repair & maintenance.