One of the most common questions we hear from commercial property owners and facility managers is straightforward: how much will it cost to replace my roof? The answer depends on several variables, including the roofing system you select, the size and complexity of your building, and the condition of the existing roof structure. This guide breaks down the real-world costs of commercial roof replacement in 2026, based on our experience completing thousands of projects across five states since 1984.
Cost Ranges by Roofing System Type
The roofing system you choose is the single largest factor in determining your total project cost. Below are typical installed cost ranges for the most common commercial roofing systems in the Midwest and Florida markets. These figures include membrane or material, insulation, fasteners, flashings, and professional installation labor.
TPO Roofing: $6.00 to $10.00 per Square Foot
TPO is one of the most popular choices for commercial flat roofs. A 60-mil mechanically attached TPO system on a standard building typically falls in the $7.00 to $8.50 range. Fully adhered systems and 80-mil membrane upgrades push costs toward the upper end. TPO's energy efficiency can generate meaningful cooling cost savings that offset the initial investment, particularly for buildings in warmer climates or with large HVAC loads.
EPDM Roofing: $5.50 to $8.50 per Square Foot
EPDM remains the most budget-friendly single-ply membrane option. A standard 60-mil EPDM system with adequate insulation typically costs between $6.00 and $7.50 per square foot installed. EPDM's lower material cost makes it especially attractive for large roof areas where even small per-square-foot savings translate into significant total project savings. Its proven longevity of 30 or more years provides excellent long-term value.
Metal Roofing: $10.00 to $15.00+ per Square Foot
Standing seam metal roofing carries a higher upfront cost but delivers exceptional longevity, often exceeding 40 to 50 years with proper maintenance. Metal roofing is commonly specified for manufacturing facilities, warehouses, and buildings where durability and low long-term maintenance costs are priorities. Retrofit metal roof systems installed over existing roofs can reduce costs by eliminating tear-off expenses.
Built-Up Roofing (BUR): $7.00 to $11.00 per Square Foot
Multi-ply built-up roofing systems consisting of alternating layers of bitumen and reinforcing fabric offer redundant waterproofing protection. BUR has been used on commercial buildings for over a century and remains popular for its durability and resistance to foot traffic. The labor-intensive installation process places BUR at a higher price point than single-ply systems, but the multi-layer construction provides excellent puncture resistance and longevity.
Modified Bitumen: $6.50 to $10.00 per Square Foot
Modified bitumen systems combine the proven reliability of built-up roofing with the convenience of sheet-based installation. Available in torch-applied, cold-adhesive, and self-adhered configurations, modified bitumen is a versatile choice for commercial buildings. Two-ply modified bitumen systems offer enhanced waterproofing redundancy at a moderate cost premium over single-ply membranes.
Factors That Affect Commercial Roof Replacement Cost
While system selection sets the baseline, several project-specific factors can significantly influence your total cost.
Roof Size and Complexity
Larger roofs generally benefit from economies of scale, resulting in lower per-square-foot costs. However, complex roof geometries with numerous penetrations (HVAC units, skylights, exhaust fans, pipes), multiple levels, or irregular shapes require more labor for detailing and flashings, which increases costs. A simple rectangular 50,000-square-foot warehouse roof will cost less per square foot than a 10,000-square-foot roof with dozens of penetrations and equipment curbs.
Access and Building Height
Buildings with difficult access, limited staging areas, or significant height increase mobilization and safety costs. Urban locations in downtown Chicago, for example, may require crane lifts, traffic control, and restricted working hours that add to the project budget. Rural or suburban sites with easy ground-level access are typically less expensive to service.
Existing Roof Removal
If the existing roof must be torn off before new installation, tear-off and disposal costs will add $1.00 to $3.00 per square foot to the project. Local building codes typically permit a maximum of two roof layers, so if your building already has two layers, a full tear-off is required. Some roofing systems, like TPO and metal, can often be installed as a recover over the existing roof when conditions allow, saving significant tear-off costs.
Insulation Requirements
Energy codes in Illinois, Wisconsin, Michigan, Indiana, and Florida specify minimum R-value requirements for roof insulation. Upgrading insulation to meet current code or exceed it for better energy performance adds material cost but delivers long-term savings through reduced heating and cooling expenses. Tapered insulation systems designed to improve drainage add further cost but eliminate ponding water, which is critical for roof longevity.
Structural Repairs
If a roof inspection reveals deteriorated decking, rusted steel, or other structural concerns, these must be addressed before the new roofing system is installed. Structural repairs can range from minor deck replacements of a few hundred dollars to major steel and concrete repairs that add tens of thousands to the project. A thorough pre-construction roof inspection by an experienced contractor like Windward Roofing identifies these issues before work begins, preventing costly surprises.
When Is Repair Cheaper Than Replacement?
Not every aging roof needs full replacement. Targeted repairs and maintenance can extend the useful life of a commercial roof and defer replacement costs. Repair is typically the more economical option when the roof system is still within its expected service life, the damage is localized to specific areas, the overall membrane condition is sound with no widespread deterioration, and repair costs remain below 30 to 40 percent of what a full replacement would cost.
Replacement becomes the better investment when the roof has exceeded 75 percent of its expected lifespan and is showing widespread wear, when multiple leak points indicate systemic failure rather than isolated damage, when energy costs have increased significantly due to compromised insulation, or when the building is being renovated, sold, or refinanced and a new roof adds substantial value.
Windward Roofing provides honest assessments of roof condition. We will recommend repair when it makes sense and replacement when the numbers clearly favor a new system. Our goal is to help you make the most cost-effective decision for your specific situation.
The ROI of a New Commercial Roof
A commercial roof replacement is a significant capital expenditure, but it delivers measurable returns. A new roof eliminates ongoing repair costs that can add up to thousands of dollars annually on an aging system. Energy-efficient systems like TPO and cool-coated metal roofing reduce heating and cooling expenses. Manufacturer warranties covering 15 to 30 years provide budget certainty and protect against unexpected costs. Additionally, a new roof can increase property value, support favorable insurance rates, and satisfy requirements for financing or property transactions.
When evaluated over a 20 to 30 year lifecycle, a properly selected and installed commercial roof typically costs less than the ongoing repairs, energy waste, and interior damage associated with deferring replacement on a failing system.
Financing Your Commercial Roof Replacement
Windward Roofing understands that budget planning is critical for commercial property owners. We provide detailed, itemized proposals that break down every cost component so you can plan accurately. Many building owners take advantage of manufacturer financing programs that spread the investment over several years. Additionally, energy-efficient roofing systems may qualify for federal tax incentives, utility rebates, or accelerated depreciation under current IRS guidelines. We recommend consulting your tax advisor to understand the specific benefits available for your project.
Ready to find out what your commercial roof replacement will cost? Contact Windward Roofing for a free, no-obligation estimate. Our team will inspect your roof, evaluate your options, and deliver a transparent proposal tailored to your building and budget.
Frequently Asked Questions
Commercial roof replacement costs typically range from $5.50 to $15.00 per square foot, depending on the roofing system selected. Single-ply membranes like EPDM start around $5.50 per square foot, TPO ranges from $6.00 to $10.00, while metal roofing systems can reach $12.00 to $15.00 or more per square foot installed.
A typical commercial roof replacement takes two to six weeks depending on the size of the roof, the complexity of the project, weather conditions, and the roofing system being installed. A 20,000 square foot single-ply membrane replacement may be completed in two to three weeks, while a larger or more complex project involving structural repairs or extensive drainage modifications may take longer.
Repairs are generally more cost-effective when the damage is localized and the overall roof system is still in serviceable condition. As a general guideline, if repair costs approach 30 to 40 percent of replacement cost or if the roof has exceeded 75 percent of its expected lifespan, replacement typically offers better long-term value. A professional roof inspection can help determine the most economical path forward.
Commercial roof replacement can offer significant tax advantages. Under current IRS guidelines, certain roof improvements may qualify for accelerated depreciation or Section 179 deductions. Additionally, energy-efficient roofing systems like TPO may qualify for federal energy tax credits. Consult your tax advisor for guidance specific to your situation.