Flat Commercial Roof Replacement Process: 5 Phases

Phase I: Inspection, Planning, and Estimating

The first phase of a flat commercial roof replacement is the inspection and planning stage. This is when your commercial roofing contractor will assess your roof’s current condition, determine what needs to be done, and develop a plan of action.

INTERIOR INSPECTION

The first thing a commercial roofing contractor will do is inspect the interior of the structure, since this is where the most damage is likely to be found. If structural damage to the inside areas has compromised their integrity, it must be repaired as part of the procedure.

Water damage is detected by looking for signs such as wall discoloration and mold accumulating in dark, damp areas of the building. The inspection crew will look for tears in the roof that expose interior spaces to the elements.

The majority of the interior examination will be conducted visually or using basic equipment such as a flashlight. The contractor will also want to go up to any higher storage areas beneath the roof to look for internal damage.

In general, the internal inspection procedure is straightforward and painless. However, the time required may vary significantly depending on the size of your business facility.

EXTERIOR INSPECTION

After that, contractors will inspect the roofing system from the outside. Getting up on the roof and closely examining the entire roofing system is an essential part of this process phase.

Visual indicators of damage that your roofing contractor will be looking for include single-membrane roof structure impact damage, damaged flashing, old and worn-out caulk, and visible signs of roof leaks and damage to the drainage system.

COST ESTIMATING

After your roof has been inspected inside and out, your roofing contractor will prepare a quote for the job. This estimate will include most or all of the following:

• Material Cost
• Labor Cost
• Inspection Report
• Scope of Work (SOW)
• Project Timeline
• Contract with Terms and Conditions

Phase II: Flat Commercial Roof Replacement – Pre-Production

During this phase, your roofing contractor’s project coordinator will take care of any necessary permits or approvals from your local government. The planning phase can take anywhere from a week to a month. Various factors impact the planning phase, from confirming architectural details to pulling the necessary permits.

Phase III: Demolition and Prep

Once the planning is complete, it’s time for demolition. The old roof material will be removed, and any damaged decking or structural elements will be repaired or replaced. This phase can be messy and disruptive, so be sure to communicate expectations to your tenants or employees ahead of time.

Your commercial roofing contractor will need to place large dumpsters in the parking lot or elsewhere on the property. A large crane will be brought in to aid in removing the old roof material and to lift the equipment and new materials needed during the installation phase.

Due to the hazards posed by the heavy equipment and the movement of materials, the area surrounding the equipment on the ground will be roped off, and hard hats will be required for anyone within the work perimeter. New roofing materials are also delivered and staged on the ground until the demolition phase is complete.

It’s important to have an alternative parking plan in place for tenants, occupants, employees, and customers before demolition begins.

Once started, this phase can take anywhere from a day to a week or more, depending on the building’s size and construction.

Phase IV: Installation

The next phase is installation, when the new roof system is put in place. This includes installing the new membrane, flashings, and drainage systems. Once everything is in place, the contractor will finish by applying the new gravel or stone ballast, if required.

This stage usually takes a few days or more to complete, but installation timelines vary by product type. Rainy weather can delay the project during installation, so crews try to plan for good weather windows to schedule installation.

Phase V: Post-Installation Inspection and Clean-up

The final phase is the post-installation inspection. This is when the contractor will check to ensure that everything was installed correctly and that there are no leaks or other issues. Local inspectors will perform an on-site inspection and sign off on the completed project. The manufacturer’s technical representative will provide you with a warranty for your new roof system.

Once the permits have been closed out, the site will be cleaned up, and all remaining equipment and materials will be cleared from the property.

Weather

Weather can disrupt even the best planning. Spring and summer storms can cause delays, especially during the installation phase, so it’s important to be patient and flexible during this process.

Your commercial roofing contractor will pay close attention to weather forecasts and may speed up or slow down a project to accommodate weather patterns.

Need a Roof Replacement? Not Sure?

Having a commercial roof replaced can be a big project, but it’s important to know what to expect. By understanding the different phases of work, you can be prepared for what’s ahead. With a bit of planning, your roof replacement will go smoothly, and you’ll have a brand new roof that will protect your property for years to come.

If you have any questions about commercial roof replacements or need to discuss your commercial roofing needs, please contact Mint Roofing at 952-473-8080. We’re always happy to help!