Case Study: Commercial Flat Roof Replacement in Dacula, GA

Flat TPO Roof

Introduction

When it comes to commercial buildings in Dacula, GA, a failing flat roof isn’t just an inconvenience—it’s a threat to your operations, your tenants, and your bottom line. Today, we’re pulling back the curtain on a recent commercial flat roof replacement project that transformed a leaky liability into a durable asset. If you’re considering a similar project, this case study will walk you through the process, the pitfalls, and the payoff.

The Problem: Persistent Leaks and Property Risk

The building owner in Dacula started noticing water stains on ceiling tiles after heavy rain. Over time, the leaks worsened, leading to:

• Disruption of tenant businesses

• Mold growth and indoor air quality concerns

• Increasing repair costs for interior finishes

A quick inspection revealed the culprit: an aging, poorly maintained flat roof with multiple patches, failing seams, and ponding water.

Assessment & Planning

Step 1: Comprehensive Roof Inspection

• Visual and hands-on examination: Checked for membrane punctures, seam failures, and soft spots in insulation.

• Hidden damage: Found deteriorated pipe boots and flashing, plus moisture trapped under the old membrane.

• Core sampling: Confirmed wet insulation in several areas, requiring full tear-off.

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Step 2: Solution Design

After reviewing options, the owner chose a high-performance single-ply TPO (thermoplastic polyolefin) system for its durability, energy efficiency, and cost-effectiveness.

The Replacement Process

1. Tear-Off and Disposal

• Removed all existing roofing layers down to the structural deck.

• Disposed of old materials in compliance with local Dacula regulations.

2. Deck Repairs

• Replaced damaged sections of decking and reinforced weak spots.

• Addressed hidden repairs, including pipe boots and deteriorated flashing, that were only visible after tear-off.

3. Insulation Installation

• Installed new, high-R-value insulation boards for improved energy performance.

• Sloped insulation was used to eliminate ponding water and direct runoff to drains.

4. TPO Membrane Application

• Mechanically fastened and heat-welded all seams for a watertight finish.

• Installed new edge metal, pipe boots, and custom-fabricated flashing around penetrations.

5. Quality Control & Final Inspection

• Thorough walk-through with the building owner.

• Infrared scan to confirm no trapped moisture.

• Issued a 20-year manufacturer’s warranty on materials and labor.

Challenges & Solutions

• Weather Delays: Unpredictable Georgia summer storms paused work several times. The crew used temporary waterproofing to protect the building between stages.

• Tenant Coordination: Work was staged outside business hours to minimize disruption.

• Hidden Repairs: Additional deck and penetration repairs were required after uncovering more damage than expected—a common issue with older flat roofs.

Results: A Leak-Free, Energy-Efficient Roof

• No leaks reported after the first heavy storm

• Lower energy bills due to better insulation and reflective TPO membrane

• Increased property value and peace of mind for the owner

• Tenants experienced zero downtime during the project

Bullet Points: Why This Flat Roof Replacement Succeeded

• Detailed inspection uncovered all problem areas

• Owner chose a durable, energy-efficient TPO system

• Hidden repairs were addressed immediately

• Work was scheduled to avoid business disruption

• Project backed by a strong manufacturer’s warranty

FAQs: Commercial Flat Roof Replacement in Dacula, GA

How long does a commercial flat roof replacement take?

Most projects take 1–2 weeks, depending on weather and building size.

What’s the best material for a flat roof in Georgia?

TPO and PVC are popular for their durability, energy efficiency, and resistance to ponding water.

Can tenants stay open during roof replacement?

Yes—careful scheduling and safety barriers can minimize disruption.

How do I know if my flat roof needs replacement?

Persistent leaks, ponding water, and visible membrane damage are all red flags. A professional inspection is the best way to know for sure.

Are warranties available?

Absolutely. Many systems offer 15–30 year warranties when installed by certified contractors.

Conclusion

This Dacula, GA commercial flat roof replacement delivered lasting protection, energy savings, and peace of mind—all without disrupting business. If your property is plagued by leaks or high energy bills, investing in a quality roof system and an experienced contractor is the best move you’ll make all year.