Partial Roof Replacement for the Toronto Roundhouse

Project Specifications

Roof area: 48,940 square feet
Deck Type: tongue and groove wood
Roof Membrane (field area): 2 ply IKO SBS modified bitumen hot asphalt applied 180-gram base sheet and thermofusible 250-gram charcoal grey granular surfaced cap sheet
Flashing Membrane (perimeter and roof upturns): 2 ply IKO SBS modified bitumen hot asphalt applied and self-adhered 180-gram base sheet and thermofusible 250-gram charcoal grey granular surfaced cap sheet.

Commercial/Retail Space Partial Roof Replacement Client

Address:

255 Bremner Blvd.

Toronto, Canada

Scope of Work

Removal and disposal of existing “coal tar pitch” roof down to the wood substrate.
Vapour retardant: 2 ply reinforced kraft paper with adhesive.
Base layer of Insulation: 3.0″ ISO mechanically fastened.
Insulation overlay: 0.5″ coated fibreboard applied in hot asphalt.

Building uses: Toronto Railway Museum, Steam Whistle Brewery

Client Goal/Purpose of Project

The client sought a partial roof replacement for the historic Roundhouse building, prioritizing the preservation of its heritage elements while addressing critical roofing issues. The goal was to ensure the structure’s long-term protection and functionality without compromising its architectural integrity. The project required thoughtful planning and execution to align with stringent heritage guidelines, ongoing business operations, and the complex design of the building itself.

Key Challenges

Working on a heritage building like the Roundhouse required navigating unique challenges that blended the demands of preserving historical elements with modern roofing standards. From managing ongoing business operations to ensuring structural integrity, each step of the project called for precision, collaboration, and innovative problem-solving.

Planning Challenges

Staged Replacement

The roof replacement had to align with other renovations occurring in the building, necessitating a phased approach that minimized disruption while maximizing efficiency.

Specialized Materials and Techniques

Given the heritage status, the planning phase required sourcing and utilizing materials that matched the original elements of the building while meeting modern performance standards.

Collaboration with Stakeholders

Close coordination with architects, technical experts, and the client was essential to meet project specifications and adhere to heritage requirements.

Management & Execution

Preservation of Historical Integrity

Maintaining the building’s heritage designation required careful handling of the original structure and materials, particularly the visible wood substrate beneath the roof. Rotten wood had to be replaced with matching materials to retain its appearance and structural integrity.

Operational Constraints

Roofing work was carried out while the Steam Whistle Brewery continued its operations, including the event space, restaurant, and outdoor patio. This required interior tarping to protect ongoing activities from construction debris or disruption.

Complex Material Application

The existing coal tar pitch residue caused issues with base sheet membrane adhesion. Custom solutions were necessary to ensure the roofing layers bonded securely without compromising durability.

Curved Design and Sloped Substrate

The unique architectural layout of the roof demanded precise membrane installation to ensure proper drainage and water management.

Completed Roof at Toronto Roundhouse

These images capture the finished roof of the Toronto Roundhouse after the partial replacement.

Solutions for the Toronto Roundhouse Partial Roof Replacement

Addressing the challenges of this project required a tailored approach that balanced the needs of the heritage building, ongoing operations, and roofing functionality. Each solution was designed to maintain the building’s historical integrity while ensuring a durable, watertight roof system.

Heritage-Appropriate Materials

Rotten wood sections were replaced with specialized lumber that matched the original tongue-and-groove substrate, preserving the visible aesthetics from the interior while restoring structural stability.

Customized Membrane Application

Collaborating with IKO’s technical team, we developed a detailed solution to address adhesion challenges caused by coal tar pitch residue. Asphalt protection boards were installed, and base flashing membranes were carefully applied to ensure a secure bond.

Interior Tarping and Protection

To support the brewery’s uninterrupted operations, we installed tarping systems to safeguard interior spaces, allowing business activities to continue seamlessly.

Phased Work Schedule

A multi-stage approach was adopted to align with ongoing renovations and minimize disruptions, ensuring smooth coordination across all project areas.

Precision Membrane Layout

The roof’s curved and sloped design was addressed by meticulously laddering materials starting at drains and eaves, optimizing water management while adhering to the building’s unique architecture.

Collaboration and Communication

Regular coordination with the client, architects, and project stakeholders ensured that all work met the heritage and functional requirements, earning commendation from the Roundhouse Development Corporation.

Contact Elite Roofing for your next roofing project!

If you’re looking for a trusted roofing partner in Toronto, Ontario, contact Elite Roofing here. We’re available 24/7 to answer all of your roofing questions. That’s the Elite Advantage.