The Unique Roofing Demands of Warehouse and Distribution Facilities
Warehouses and distribution centers represent some of the most challenging commercial roofing projects in the industry. These buildings feature enormous roof areas that can span 100,000 square feet or more on a single structure, creating unique challenges related to material logistics, drainage engineering, and project coordination. Unlike smaller commercial buildings where a roofing crew can complete work in a matter of days, warehouse re-roofing projects require careful phasing, material staging, and scheduling to avoid disrupting the constant flow of goods moving through loading docks and receiving areas below.
Windward Roofing and Construction has been serving warehouse and distribution facility owners across Illinois, Wisconsin, Michigan, Indiana, and Florida since 1984. Over four decades, we have developed specialized expertise in managing large-footprint roofing projects that demand precision planning and flawless execution. Our team understands that every hour of downtime in a logistics operation costs money, which is why we design our project plans around your operational schedule rather than asking you to work around ours.
Common Roofing Challenges for Warehouses
Massive Roof Areas and Drainage
The sheer scale of warehouse roofs introduces drainage challenges that smaller buildings simply do not face. A 200,000-square-foot roof can collect thousands of gallons of water during a single rainstorm, and if drainage systems are not properly designed and maintained, ponding water will accelerate membrane deterioration, add structural load, and eventually cause leaks. Windward specifies tapered insulation systems that direct water to internal drains, and we ensure that drain capacity is sufficient for the roof area being served. On existing buildings where drainage is inadequate, we design retrofit solutions that eliminate chronic ponding problems.
Loading Dock and Edge Conditions
The perimeter of a warehouse roof is subjected to significantly higher wind uplift forces than the central field area. Dock doors that open and close throughout the day create pressure differentials that can stress roofing membranes and flashings at the roof edge. Windward installs enhanced perimeter fastening patterns and fully adhered edge details that resist these forces. We pay particular attention to the transition between the roof membrane and the dock canopy or awning structures that are common on distribution facilities, as these junctions are frequent sources of leaks when not properly detailed.
Rooftop Equipment and Penetrations
Modern warehouses are equipped with extensive rooftop mechanical systems including HVAC units, exhaust fans, skylights, and smoke vents. Each penetration through the roof membrane is a potential failure point if not properly flashed and sealed. Windward's detail crews are experienced in fabricating and installing custom flashings for every type of rooftop penetration found on warehouse and distribution buildings. We use prefabricated pipe boots, curb adapters, and pitch pans that meet manufacturer specifications and are covered under the roof warranty.
Minimizing Operational Disruption
Perhaps the greatest concern for warehouse operators is the impact of roofing work on daily operations. Forklifts need access to aisles, trucks need access to docks, and temperature-sensitive goods need continuous climate control. Windward addresses these concerns through detailed pre-construction planning. We divide large roofs into work zones and phase the project so that only one section is under construction at any given time. Materials are staged to avoid blocking dock areas, and our crews coordinate with your facility management team on a daily basis to accommodate changes in shipping and receiving schedules.
Recommended Roofing Systems for Warehouses
TPO Single-Ply Membranes
TPO is the most widely specified roofing system for warehouse and distribution buildings, and for good reason. Its heat-welded seams create a monolithic waterproof barrier across even the largest roof areas, and its white reflective surface reduces cooling costs in facilities where climate control is critical for product storage. TPO membranes are available in wide sheets that cover more area per roll, reducing the total number of seams and accelerating installation on large-footprint buildings. Windward installs TPO systems from Carlisle, Versico, and other leading manufacturers with full warranty coverage.
EPDM Rubber Roofing
EPDM remains a proven choice for warehouse roofing, particularly in the Midwest where its exceptional flexibility in cold temperatures prevents cracking during harsh winters. EPDM membranes are available in sheets up to 50 feet wide, making them ideal for covering large warehouse roof areas with minimal seams. The material's resistance to UV radiation and ozone gives it a service life that can exceed 30 years with proper maintenance. Windward installs both mechanically attached and fully adhered EPDM systems depending on the structural requirements of the building.
Metal Roofing Systems
Standing seam metal roofing is an excellent option for warehouses that require long-term durability with minimal maintenance. Metal panels can span long distances without support, making them well-suited for the open structural bays typical of warehouse construction. Metal roofing also provides superior resistance to fire, wind, and impact damage. For distribution centers in hurricane-prone areas of Florida, Windward installs metal systems that meet Miami-Dade wind code requirements for maximum protection.
Why Windward for Your Warehouse Roofing Project
Windward Roofing has completed roofing projects on hundreds of warehouse and distribution facilities throughout our five-state service area. From 50,000-square-foot regional warehouses to multi-building logistics campuses exceeding one million square feet, our project management team has the experience to deliver large-scale projects on time, within budget, and without disrupting your supply chain. We maintain certified installer status with every major membrane manufacturer, enabling us to offer comprehensive warranty programs that protect your roofing investment for decades.
Our crews are OSHA-trained and follow strict safety protocols that protect both our workers and your employees. We carry comprehensive general liability and workers' compensation insurance, and we provide certificates of insurance to every client before work begins. When you choose Windward for your warehouse roofing project, you get a single point of accountability from the initial roof assessment through final warranty documentation.