Building Height: 30′
Total Roof Area: 101,358 sq ft
Deck Substrate: Metal deck
Vapour Retarder: Kraft paper
Original insulation: 2” fibreglass
New Insulation: 2.5” polyisocyanurate and 0.5” fibreboard cover board applied in roofing asphalt
Membrane Type: 2 ply sand-surfaced SBS modified bitumen membrane, mopped with hot asphalt and pea gravel embedded in an asphalt pour
Ballast: Gravel
Flashings: 2-Ply SBS modified bitumen with granular cap sheet
Metal Coping: 26 gauge dark brown pre-painted metal
The project was a flat roof replacement for a shopping mall in Cobourg. After multiple active leaks and service call visits over the couple of years, the landlord was no longer satisfied with the roof’s performance. The aging flat roof had extensive leaks and was in poor condition overall. Several unique challenges also required innovative solutions.
Reviewing the budget, the landlord of the shopping mall in Cobourg asked about the option of roof recovery. The alternative was a total roof replacement, which would significantly increase the budget.
Securing pricing early for the flat roof replacement in Cobourg would protect against cost increases due to anticipated tariffs. This required early ordering, highly coordinated delivery and accommodating the weight of materials stored on the roof simultaneously. We shipped a larger initial load of materials for this reason.
It’s unusual to store so much material on the roof simultaneously. The Ontario Building Code for Loading requires roofers to properly balance roof load throughout the construction process for structural integrity and safety. The larger initial material load [distributed for weight across the roof replacement area], existing fibreglass insulation on the OLD roof and membrane condition all increased the risk during the flat roof replacement
Walking across the OLD roof and transporting materials during the shopping mall roof replacement would likely damage the membrane on the OLD roof. We anticipated the need for multiple setups to complete work in the sequence the client requested.
We designed and built movable plywood walkways that served multiple purposes during the flat roof replacement in Cobourg:
To ensure watertightness, HVAC penetrations from over 30 units needed to be removed and replaced while coordinating with the client’s preferred HVAC contractor. This process affects productivity, typically adding to the time of a flat roof replacement.
Our ground set up areas were often a far distance from the daily working areas. We had a limited working area at the front of the mall concourse area. We had to plan the work carefully to avoid excessive traffic on the old roof.
Working with the over 350 linear feet of atrium skylights was in the scope of work (SOW) during the shopping mall roof replacement. However, we needed to protect our workers from skylight fall risks. We also needed to prevent damage to the skylights.
After a thorough roof assessment, including a review of the results of an infrared scan, we agreed with the client that a flat roof replacement was necessary. The factors included:
We designed, built and hung A-frame plywood covers over the peaked skylights. This flat roof replacement solution was cost-effective, limited delay, and allowed for easy removal of the covers.
The Elite team overcame the unique challenges of this flat roof replacement in Cobourg through innovation, experience and technical knowledge. We resolved all the issues we faced during planning and implementation, and currently on track to complete this ongoing project on time and within budget.
We attribute much of the success to the factors below:
With any flat roof replacement, expect the unexpected. Roofers often face on-the-job challenges, making experience a primary consideration when hiring your roofing contractor. With 60+ years of experience, Elite Roofing has demonstrated a commitment to achieving the best results for our clients, always acting with full transparency and integrity.
Experienced commercial roof contractors are best prepared to adapt to new challenges while maintaining the quality you deserve. During the flat roof replacement project in Cobourg, the Elite team went beyond expectations in meeting project objectives and ensuring client satisfaction.
