1. Inspection and Planning
- Assessment: Check the existing roof condition, structure, and deck. Contractors may perform core cuts to test moisture levels.
- Design: Select appropriate materials (like TPO, EPDM, or metal) based on building codes and climate.
- Permits: Obtain necessary local building and zoning approvals.
2. Removal and Preparation
- Tear-off: Strip away the old roofing membrane and wet insulation down to the bare roof deck.
- Repair: Fix any damaged steel, wood, or concrete decking components.
- Cleaning: Clear all debris to create a smooth, safe work surface.
3. Insulation and Vapor Barrier
- Vapor retarder: Install a protective layer to stop indoor condensation from reaching the roof.
- Insulation boards: Lay down high-performance rigid foam or ISO boards for thermal resistance.
- Fastening: Glue or mechanically screw the insulation layers to the roof deck.
4. Membrane Installation
- Laying the membrane: Unroll the roofing material (such as single-ply TPO, EPDM, or multi-ply BUR).
- Securing: Fasten the membrane using adhesives, mechanical screws, or heat-welding depending on the system type.
- Sealing seams: Use a hot-air gun or solvent to seal all joints tightly.
5. Flashing and Drainage
- Penetrations: Flash around HVAC units, pipes, and vents to stop leaks.
- Drainage: Install tapered insulation near drains and scuppers to prevent water pooling.
6. Final Inspection
- Quality check: Test seam integrity and verify proper water drainage.
- Cleanup: Remove remaining job-site debris and provide warranty documentation.
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