Commercial Roof Replacement and Re-Roofing Services

When Does a Commercial Roof Need Replacement?

Every commercial roofing system has a finite service life. Even the best-maintained roofs will eventually reach a point where continued repairs become more expensive than replacement and no longer provide reliable protection. Recognizing the signs that replacement is necessary helps building owners make proactive decisions rather than reacting to emergency failures that can damage inventory, disrupt operations, and create liability exposure.

Windward Roofing & Construction has evaluated thousands of commercial roofs across Illinois, Wisconsin, Michigan, Indiana, and Florida during our 40-plus years in business. Based on that experience, we recommend building owners consider replacement when they observe the following conditions:

• Recurring leaks: When leaks persist despite multiple repair attempts, the underlying membrane has likely deteriorated beyond the point where localized repairs can restore watertight integrity.
• Widespread membrane deterioration: Extensive cracking, splitting, blistering, or loss of granule surfacing across large areas of the roof indicates systemic material failure rather than isolated damage.
• Saturated insulation: Infrared moisture scans that reveal moisture throughout the insulation layer mean the system has lost its thermal performance and is adding dead load to the structure. Wet insulation cannot be effectively dried and must be removed.
• Excessive ponding water: Chronic ponding that does not drain within 48 hours after rain accelerates membrane degradation, adds structural load, and creates conditions for biological growth.
• Visible structural issues: Sagging deck areas, deteriorated metal decking, and compromised structural connections indicate that the roofing problem extends beyond the membrane and insulation.
• Age beyond expected service life: If the roof has reached or exceeded the manufacturer's expected service life for the installed system, the risk of failure increases substantially with each passing year.

Tear-Off vs. Overlay: Choosing the Right Approach

When a commercial roof needs replacement, there are two fundamental approaches: a complete tear-off or an overlay. Each has distinct advantages, and Windward Roofing helps building owners understand which approach best serves their situation.

Complete Tear-Off

A tear-off involves removing all existing roofing materials, including the membrane, insulation, and vapor retarder, down to the structural deck. This exposes the entire deck surface for inspection, allowing the identification and repair of any deteriorated decking, corroded fasteners, or structural deficiencies before the new system is installed. A tear-off is the most thorough approach and is required when moisture surveys indicate widespread insulation saturation, when the existing system has reached its maximum allowable number of layers under local building codes, or when the building owner wants the longest possible warranty and service life from the new installation.

Overlay (Recover)

An overlay installs a new roofing membrane and, in many cases, additional insulation directly over the existing roof system. This approach is faster, less expensive, and generates less waste than a tear-off because the demolition phase is eliminated. Overlays are appropriate when moisture testing confirms that the existing insulation is dry, the current membrane is well-adhered and provides a stable substrate, and local building codes permit an additional layer. Most jurisdictions allow a maximum of two roofing layers before a tear-off is required.

Windward Roofing conducts comprehensive moisture surveys using infrared thermography and core cuts to determine which approach is appropriate for each project. We never recommend an overlay when conditions indicate that the existing system should be removed, and we provide building owners with transparent information to support their decision.

Roof System Options for Replacement

A roof replacement is an opportunity to upgrade to a system that better serves the building's current and future needs. Windward installs all major commercial roofing systems and works with leading manufacturers to provide warrantied solutions:

• TPO (Thermoplastic Polyolefin): The most widely installed commercial roofing membrane, offering excellent UV resistance, energy-efficient white reflectivity, and heat-welded seams for long-term waterproofing. Available from Carlisle, Versico, Elevate, and GAF.
• EPDM (Ethylene Propylene Diene Monomer): A proven rubber membrane with outstanding flexibility and resistance to thermal cycling, available in fully adhered, mechanically attached, or ballasted configurations. Available from Carlisle, Elevate, and IKO.
• Metal Roofing: Standing seam and through-fastened metal systems for buildings requiring maximum longevity, steep-slope aesthetics, or architectural metal panel designs.
• Modified Bitumen: Multi-layer systems using SBS or APP modified asphalt membranes, providing redundant waterproofing and excellent puncture resistance for high-traffic roofs.
• Built-Up Roofing (BUR): Traditional multi-ply systems with alternating layers of asphalt and reinforcing fabrics, delivering time-tested waterproofing performance for buildings requiring maximum durability.
• SPF Spray Foam: Seamless spray-applied systems that combine waterproofing and insulation in a single application, ideal for buildings where energy efficiency is a top priority.

The Replacement Process: Assessment to Completion

Windward Roofing follows a structured process for every roof replacement project to ensure quality results and a smooth experience for building owners and facility managers.

Step 1: Comprehensive Roof Assessment

Our team conducts a thorough on-site evaluation including visual inspection of the entire roof surface, flashings, and penetrations; infrared moisture scanning to map areas of trapped moisture; core cuts to verify insulation type, thickness, and condition; structural assessment of the deck and supporting structure; and documentation of all rooftop equipment, penetrations, and drainage conditions.

Step 2: System Recommendation and Proposal

Based on the assessment findings, we develop a detailed proposal that includes our recommended roofing system with supporting rationale, a complete scope of work with specifications, a project schedule with key milestones, warranty options with cost comparisons, and a plan for minimizing disruption to building operations.

Step 3: Preconstruction Planning

After contract execution, our project manager coordinates material procurement, permits, crew scheduling, and site logistics. We hold a preconstruction meeting with the building owner or facility manager to review the work plan, establish communication protocols, and address any operational concerns such as restricted work hours or sensitive areas below the roof.

Step 4: Demolition and Deck Preparation

For tear-off projects, our crews remove existing materials in controlled sections to limit the area of exposed deck at any given time. Debris is chuted directly into dumpsters to keep the ground-level work area clean. The exposed deck is inspected, and any deteriorated sections are repaired or replaced before new materials are installed.

Step 5: New System Installation

New insulation, vapor retarders, and roofing membrane are installed per manufacturer specifications and project drawings. Our foremen verify material thickness, adhesion, seam integrity, and flashing details throughout the installation. Third-party quality control inspections are coordinated as required by the warranty specification.

Step 6: Final Inspection and Closeout

Upon completion, our quality control team conducts a comprehensive punch-list walk with the building owner. We process all manufacturer warranty documentation, provide as-built drawings, and deliver a maintenance guide for the new system. A follow-up inspection is scheduled for 12 months after completion to verify system performance.

Minimizing Business Disruption

Windward Roofing understands that a roof replacement cannot shut down your business. Our project planning specifically addresses operational continuity. We work in sections to maintain watertight conditions across the roof at all times, using temporary waterproofing at the end of each work day. Noisy operations such as equipment mobilization and material hoisting are scheduled during appropriate hours. Interior protection protocols are implemented for sensitive areas directly below the work zone, including dust barriers, equipment covers, and inventory relocation when necessary. Our project managers maintain daily communication with facility managers to coordinate any work that may affect building operations.

Why Choose Windward Roofing for Roof Replacement

With over 40 years of commercial roofing experience, Windward Roofing & Construction has completed thousands of roof replacement projects ranging from 5,000 to over 500,000 square feet. Our manufacturer certifications with Carlisle, Versico, Elevate, Johns Manville, ERC Systems, Sika, GAF, Tremco, and IKO allow us to provide the most comprehensive warranty options in the industry. From the initial assessment through post-installation follow-up, our team is committed to delivering a replacement roof that protects your building, improves your energy performance, and provides decades of reliable service.

Frequently Asked Questions