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Commercial roofing

Commercial roofs are capital assets. They should be managed like one.

Engineer-led condition assessments, service life planning, and honest repair-versus-replace analysis for Central Texas commercial properties.

Same-day response · No obligation.

What a commercial client actually needs

Usually not a roof. Usually a number, in writing, that survives review.

Jose Puente is a Civil Engineer, and that credential carries different weight here than it does on a residential job. A homeowner may reasonably not care. A facility manager, property manager, or building owner does, because they read engineered documents as part of the job, they answer to an owner or a board, and what they hand upward has to hold up when someone else reads it.

Most commercial roof problems are not technical mysteries. They are budget-timing problems. The roof is 19 years old, it leaks in three places after heavy rain, and the question is not what is wrong — it is whether this is a repair year or a replacement year, and what number goes into the capital plan if it is the latter. A roof that fails unexpectedly in the middle of a fiscal year costs far more than the same roof replaced on schedule: emergency mobilization, interior damage, tenant claims, and a purchase made without competitive bidding.

So the deliverable is a document, not a proposal. A written condition assessment with remaining service life by roof section, a repair-versus-replace analysis, and a defensible replacement figure with an expected year attached. We write it on the assumption that the person reading it is not the person who commissioned it — an owner, a board, a lender, or an asset manager reviewing a portfolio — and that they will want to see the basis for the conclusion rather than take it on trust.

The corollary is that we will tell you when there is nothing to do. A survey concluding that a roof has eight years left and needs $4,000 of penetration work is a useful result, and it is the result more often than the industry admits.

Commercial metal roofing

The dominant system in Central Texas commercial, and the one where the specification differences actually matter.

Metal dominates commercial roofing in this region for three reasons that are all economic rather than aesthetic. Service life is long enough to outlast two membrane cycles. The maintenance burden is low and predictable, which matters more to a facility budget than a lower installed cost does. And on hail exposure of the kind Central Texas delivers, a properly specified metal panel takes impact that would open a single-ply membrane, though it may take it cosmetically — which is its own insurance conversation.

The decision that actually matters is fastener strategy, because that is what determines the maintenance schedule for the next several decades.

Standing seam (concealed fastener)
Panels joined by raised seams and held with clips that allow the metal to move as it heats and cools, with no fasteners penetrating the water plane. This is the long-term system: 40-plus year service life, minimal maintenance, and no fastener population to re-torque. It carries the highest upfront cost, and on a building held long-term that cost is usually recovered.
Exposed fastener (R-panel / PBR)
Panels screwed directly through the face into purlins with neoprene-washered fasteners. Lower cost, faster installation, and the standard on warehouses, agricultural buildings, and light industrial. The tradeoff is structural: every fastener is a penetration, and daily thermal cycling gradually walks them loose and compresses the washers. Plan on a re-torque and washer replacement cycle roughly every 8 to 12 years.
Metal retrofit over existing metal
A new panel system installed over a failing metal roof on a sub-purlin framing system, without tearoff. The building keeps operating, there is no exposed-deck risk, and insulation can be added in the cavity. On a large warehouse where the real cost of replacement is downtime rather than materials, this is frequently the correct answer.

On a building you intend to hold, run the lifecycle number rather than the bid number. Standing seam at a meaningfully higher installed cost with no fastener maintenance and a 40-year life usually beats exposed fastener with two re-torque cycles and an earlier replacement. On a building you expect to sell inside a decade, the arithmetic reverses.

Low-slope systems

Four assemblies cover nearly everything flat in Central Texas. Each is good at something and fails in a characteristic way.

TPO

Single-ply thermoplastic with heat-welded seams, so the seam is as strong as the sheet. The reflective white surface reduces cooling load measurably in this climate, which shows up on the utility bill of a large single-story building.

Membrane thickness decides longevity — 45 mil is a value spec that ages faster here than 60 mil. Punctures from foot traffic and rooftop trades are the common failure, and repairs require a qualified welder rather than a caulk tube.

The current default for new low-slope commercial.

Modified bitumen

Asphalt-based membrane in torch-applied, cold-applied, or self-adhered form. Durable, multi-ply, and genuinely repairable with common materials. It performs well on roofs with heavy foot traffic and dense penetration fields, where a single-ply gets abused.

Heavier and slower to install. Torch application carries fire risk and is inappropriate over some assemblies, and dark surfacing runs hotter than TPO unless it is coated.

Best where the roof takes abuse.

EPDM

Synthetic rubber single-ply with the longest field track record of any modern membrane. Very tolerant of thermal movement and simple to install over large uninterrupted areas.

Seams were the historic weak point; modern seam tapes have improved that considerably but the joint is still where it fails. The black surface absorbs heat, which in San Antonio is a real cooling-load and aging consideration rather than a theoretical one.

Proven, but weigh the black surface here.

Built-up roofing (BUR)

The traditional multi-ply assembly of felts, bitumen, and gravel surfacing. Redundant by design — several plies means no single layer is the whole waterproofing — and remarkably long-lived when it was built well.

Heavy, slow, difficult to inspect because the gravel hides the membrane, and awkward to repair. Still found on older Central Texas buildings; rarely specified new.

Common on legacy buildings, rarely new.

What a roof survey includes

Six steps, in order, producing a document you own.

  1. 1
    Moisture investigation

    Core sampling or non-destructive scanning — infrared or capacitance — to find wet insulation below the membrane. This is the step most often skipped, and it is the one that determines whether recover, coating, or full replacement is honest.

  2. 2
    Penetration and termination inventory

    Every curb, pipe, drain, scupper, vent, wall termination, and edge metal detail documented and photographed. Most low-slope leaks originate at these details rather than in the field of the membrane.

  3. 3
    Drainage and ponding assessment

    Slope, drain condition and capacity, and where water actually stands after rainfall. Standing water is the leading cause of premature low-slope failure, so this drives more of the recommendation than anything else on the list.

  4. 4
    Substrate and deck condition

    Deck type, fastener pull-out where accessible, insulation type and thickness against current code, and any structural deflection. Deck condition frequently changes the cost basis of the entire project.

  5. 5
    Remaining service life estimate

    A written estimate in years, by roof section rather than for the building as a whole, because a building rarely fails uniformly. Sections get their own expected replacement year.

  6. 6
    Repair-versus-replace analysis with budget figures

    What repair costs, what it buys in years, what replacement costs, and which is the better use of capital given how long the asset will be held. Numbers written to be defensible in a budget review.

The survey is delivered as a document the client owns and can circulate, including when the conclusion is that the roof has years of life left and no work is warranted. We would rather be the firm you call in three years with a file already on record than the one that sold a replacement early.

Ponding water, and why it matters more than anything else

If you manage one thing on a low-slope roof, manage where the water goes after the rain stops.

The industry benchmark is 48 hours. Water still standing 48 hours after rainfall, in weather that would otherwise dry the roof, is ponding — and it is the leading driver of premature low-slope membrane failure. Four separate mechanisms are at work. UV and chemical degradation accelerate under standing water, particularly on asphaltic surfaces. Load accumulates: water weighs about 5.2 pounds per square foot per inch of depth, so two inches across a 40-by-40 foot low area is roughly 16,600 pounds sitting on a deck that was designed for a fraction of it. Standing water finds seams and laps that shed fine under sheet flow. And it grows vegetation and biological matter, whose roots and acids attack the membrane directly.

The load mechanism is also self-reinforcing, which is why it deserves attention rather than tolerance. Water collects in a low spot, the added weight deflects the deck slightly, the deeper low spot collects more water, and the cycle continues. In extreme cases that ends in structural failure; far more often it ends in a membrane failure five to ten years early.

The causes are a short list, and they are diagnosable:

  • Inadequate slope — the roof was built at or near dead level, common on older buildings constructed before positive drainage was standard practice.
  • Clogged, crushed, or undersized drains and scuppers. Drain maintenance is the cheapest roofing work that exists and the most frequently deferred.
  • Deck deflection between structural members, often from rooftop equipment added years after the building was designed.
  • Insulation compressed under repeated foot traffic on service routes to rooftop units, creating low areas exactly where the traffic is heaviest.

Fixes scale with cause. Drain cleaning and strainer replacement is maintenance and costs little. Adding drains or scuppers at low points is a modest project. Crickets between drains and behind curbs handle localized areas. A tapered insulation package rebuilds positive slope across the whole roof and is the correct answer when the building simply was not built to drain — it is a real cost, and it is done during replacement rather than as a standalone project. Walkway pads on service routes prevent the compression version from recurring.

Who we work with

Building type predicts the failure mode more reliably than building age does.

Retail and strip centers

Multiple tenants under one membrane, so a single leak becomes several tenant complaints and a lease exposure. Roof sections often age differently because of staggered build-out and HVAC replacement.

Warehouses and light industrial

Large uninterrupted spans where tearoff downtime, not material, dominates cost. Metal retrofit and phased recover usually beat full replacement on total cost to the business.

Offices and medical

Dense rooftop mechanical, constant service traffic, and zero tolerance for interior disruption or odor migrating through air intakes. Sequencing matters as much as the specification.

Churches and schools

Steep-slope and low-slope on one building, long-held assets, and volunteer or board decision-making that needs documentation. Work windows are narrow and non-negotiable.

Restaurants

Grease-laden kitchen exhaust degrades membrane and sealants around the hood curbs faster than anywhere else on the roof. Grease containment and a resistant membrane in that zone are not optional.

Multi-family

Occupied units directly below the work, with noise, odor, and access complaints escalating quickly. Building-by-building phasing and written resident notice are part of the scope, not an afterthought.

We work across the San Antonio metro and out through Helotes, Boerne, Kerrville, New Braunfels, Seguin, and Cibolo. Portfolio clients with buildings in more than one of those markets get one assessment covering all of them, sequenced by fiscal year.

Commercial roofing FAQs

Commercial work is priced per square foot, not per 100-square-foot 'square' the way residential is. Broad Central Texas ranges: TPO and EPDM roughly $6 to $11 per square foot installed, modified bitumen roughly $7 to $12, exposed-fastener metal roughly $9 to $14, and standing seam roughly $14 to $25. Variance is driven less by the membrane than by access, building height, deck condition, tearoff versus recover, insulation thickness required by code, and whether the work has to happen outside operating hours.

Standing seam metal 40 or more years. Exposed-fastener metal 25 to 35 years, with fastener re-torquing on an 8 to 12 year cycle. TPO 20 to 30 years depending on membrane thickness — 60 mil materially outlives 45 mil in this UV climate. Modified bitumen 20 to 25 years. EPDM 20 to 30 years, with seam condition being the deciding factor. Built-up roofing 20 to 30 years, though most of what remains locally is well into the back half of that.

Frequently, and it is often the correct capital decision. If the insulation below the membrane is dry, the deck is sound, and the failures are localized at penetrations, seams, or terminations, repair buys real years at a fraction of replacement cost. The condition that changes the answer is saturated insulation: wet insulation does not dry out under a membrane, it keeps degrading the deck, and patching over it defers a larger number rather than reducing it.

A survey is a documented condition assessment: moisture scanning or core sampling, penetration and termination inventory, drainage and ponding assessment, deck and substrate condition, a remaining-service-life estimate, and a repair-versus-replace analysis with budget figures. On typical Central Texas commercial buildings it runs from no charge on smaller single-tenant properties up to a few thousand dollars on large or multi-building portfolios where core sampling and infrared work are involved. We quote it before we do it.

Yes, and on occupied retail, medical, and multi-family buildings it is usually a requirement rather than a preference. Work gets sequenced around business hours, deliveries, and tenant access, with staging and material handling planned so that no section of roof is left open at the end of a shift. Night and weekend phases cost more, and we tell you what that premium is up front rather than discovering it mid-project.

Sometimes, and it is legitimate when it is legitimate. A silicone or acrylic restoration coating over a sound substrate with dry insulation and intact seams can add 10 to 15 years and is often renewable after that. What a coating cannot do is fix wet insulation, a deteriorated deck, structural ponding, or failing seams — it seals those problems in and hides them from view. Coatings are among the most oversold products in commercial roofing, so we scan for moisture before recommending one and decline the job when the substrate does not support it.

The policies are usually different instruments. Commercial policies commonly carry percentage-of-value wind and hail deductibles rather than flat amounts, cosmetic damage exclusions that specifically affect metal roofs, and actual cash value settlements on roofs past a stated age. Claims are also more document-driven: adjusters and engineers on the carrier's side expect measurements, test squares, moisture data, and dated photographs. Our insurance page covers the process, and commercial claims reward preparation far more than residential ones do.

Two separate instruments. Manufacturer warranties on qualifying systems — including NDL (no dollar limit) warranties on TPO and modified bitumen when installed to spec by a certified applicator and inspected by the manufacturer — typically 10 to 20 years. Separately, our own workmanship warranty covers installation. They cover different failures, and a manufacturer warranty on a poorly installed roof pays for very little in practice.

Yes. A large share of our commercial work comes through property managers, asset managers, and general contractors. We carry commercial general liability and workers compensation, provide certificates of insurance naming additional insureds, submit to the reporting format the manager uses, and write documentation on the assumption that an owner or board who never met us will read it.

Yes, and it is worth coordinating deliberately. Most commercial membrane damage we find is mechanical damage from other trades: dropped tools, dragged equipment, unprotected foot traffic to rooftop units, and improperly flashed new curbs and conduit. We install walkway pads on service routes, flash new penetrations correctly, and inspect after other trades have worked on the roof.

It is assessed differently than residential. On single-ply and modified bitumen the question is membrane fracture and displaced granules or coating, documented through test squares. On metal the question is whether denting is functional — deformed panels, compromised seams and fasteners, damaged flashing — or purely cosmetic, which many commercial policies exclude outright. Our hail damage page explains how functional damage is documented, and on commercial buildings that documentation is the whole claim.

That is the core deliverable. A written condition assessment with remaining service life by roof section, a repair-versus-replace analysis, and a defensible replacement figure with an expected year, so the number can go into a capital plan and survive review. Multi-building portfolios get section-by-section sequencing so replacements can be phased across fiscal years rather than landing at once.

Less than most owners expect on a low-slope recover, more than they expect on a full tearoff over a metal deck. Tearoff generates noise directly above occupied space, and adhesive and torch work can drive odor into a building through rooftop air intakes, which is the complaint that actually escalates. We phase by section, shut down or shield affected intakes during odor-producing work, and give tenants a written schedule before mobilization.

An inspection answers a question you already have — usually about a specific leak — and produces a repair recommendation. A survey characterizes the entire asset: moisture conditions, drainage, every penetration and termination, deck condition, and a remaining service life estimate with budget numbers. An inspection tells you what to do this week. A survey tells you what to budget for over the next several years.
Get the number before you need it.

Send us the address and the roof age. We will tell you what a survey would cover and what it costs, before you commit to anything.