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Old 05-27-2012, 09:13 AM   #1
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Flat Industrial Roof


We have about a 30 year old flat industrial roof. It appears to be decking covered in black tar mixed with gravel, and loose gravel on top of that. We have had leaks in the same general area over the past 15 years. We have had patches done where they scrape the loose gravel away, but over time the edges of the patches have cracked and the roof still leaks. We can not afford a new roof and so we have been getting proposals from roofing companies for a better, but cost effective solution. The entire roof is 12,000 sq. ft. The area of concern is about 2,000 sq. ft. The problem is they all disagree with each other. Company "A" says he can use liquid rubber, and mix the loose gravel back on top of it, to either patch over the multiple patches we already had done for about $2400, or go to the perimeter of the building to capture the front 5,000 sq. ft. area for about $4600. Company "B" says in the 5,000 sq.ft. area he would remove the loose gravel, torch down the black rolls of flashing and then coat it with the silver paint for about $7000. Company "C" says in the 5,000 sq.ft. area he would install a shingle like covering for about $8400. Company "A" says without the sub boards which we can not afford, the proposals from companies "B" and "C" would not work. Companies "B" and "C" say that the liquid rubber company "A" is proposing will not work as it will crack. What do you think is the best, most cost effective measure? Thank you!

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Old 05-27-2012, 09:24 AM   #2
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Flat Industrial Roof


Scrape the gravel off and instal another couple of layers of BUR then put the gravel back over it.

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Old 05-30-2012, 07:50 PM   #3
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Flat Industrial Roof


A 3 lb closed cell spray foam roof is best. payback is 4 years or less when you consider the energy savings. These roofs come with a guarantee for 50 years to not leak or deteriorate which includes labor and materials. Maintenance is required which involves power washing and re-coating every 15 years. Cost is very close to $500 a square.
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Old 05-30-2012, 07:57 PM   #4
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Flat Industrial Roof


The asphalt on you roof has run its coarse the oils in the asphalt have been drained by the elements in it's 30 year. You roof is now like a cracker, it will break apart by just walking on it , repairs at this point are useless for you will just be doing them every 6 months or so. If you only have 1 roof you can get an est. on a recovery roof. Remove all gravel and lay down a new roof over the old 1
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Old 06-05-2012, 11:37 AM   #5
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Flat Industrial Roof


Recover the whole roof if you can. Install 1/2 cover board and roof of your choice. A large repair will get you by for awhile but no idea how long. None of the proposals above are right. Droping a coating on it will not help. The proper fix would be to scrap the gravel off in the area, mop two or so plys on the area and re-gravel.
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