When Corvallis Manor Nursing & Rehabilitation Center reached out to us at Flat Roof LLC, they were in a real bind. Their facility, located in the heart of Corvallis, Oregon, was suffering from persistent leaks, despite having a fairly new TPO membrane roof. It was clear they needed help fast, and our team was ready to answer the call.
We sent out our inspector to assess the situation, and it didn't take long to identify the problem. The previous contractor had made a critical error in the installation process, failing to properly terminate the roof at the perimeter. This oversight allowed water to seep in through the edges, traveling horizontally beneath the metal flashing. Over time, the moisture had begun to wreak havoc, causing the plywood substrate to deteriorate and creating a perfect environment for mold to grow within the insulation layer.
Faced with the urgency of the situation and the potential health hazards at play, our team wasted no time in crafting a comprehensive solution. The project would require a partial tear-off of the existing roof, removing the affected membrane and plywood. In total, we'd need to replace 800 square feet of plywood and 1,400 square feet of TPO membrane. But the real key to success would lie in rebuilding the perimeter correctly, ensuring a proper termination that would prevent any future issues.
Of course, a project of this scale comes with its own unique challenges. We'd need to work efficiently to minimize disruption to the facility's operations, all while staying true to our commitment to quality craftsmanship. But our team was up for the challenge, and we set to work with a clear plan in mind.
The first step was to carefully remove the damaged materials, taking care not to cause any further harm to the structure. As we peeled back the layers, we discovered that the extent of the water damage was even greater than we'd initially anticipated. We ended up submitting a change order for additional plywood and insulation replacement, but we knew it was a necessary step to ensure the longevity of the new roof.
With the old materials removed, we set about rebuilding the roof from the ground up. We started with a fresh layer of high-quality plywood, followed by a fire-rated separator sheet for added protection. Finally, we installed a brand-new TPO membrane, taking great care to properly terminate it at the perimeter. Our secret weapon in this process was our state-of-the-art heat welding technology, which allowed us to weld the TPO seams at 7-900 degrees Fahrenheit depending on the current temperature outside. This extra step would ensure a seamless, watertight seal that would stand up to even the harshest weather conditions.
Thermoplastic Polyolefin (TPO) roofing stands out in the commercial roofing market primarily due to its welding process, which enhances both its durability and reliability. Unlike other roofing materials that might be secured with adhesives or mechanical fasteners, TPO membranes are heat-welded at the seams. This process creates a monolithic, seamless surface, which greatly reduces the risk of leaks and withstands environmental factors such as extreme temperatures and UV exposure more effectively. In contrast, other systems that rely on less robust joining techniques can be more susceptible to failure, particularly under challenging weather conditions or over extended periods of time. This makes TPO an increasingly popular choice for those seeking a dependable and long-lasting roofing solution.
Throughout the project, we kept in close communication with the team at Corvallis Manor, providing regular updates and promptly addressing any concerns that arose. It was a true partnership, and one that we knew would lead to a successful outcome.
In the end, we were able to complete the entire project in just four days—a testament to the skill and dedication of our team. The results spoke for themselves: a beautiful, durable flat roof that would provide reliable protection for years to come. But more than that, we'd given Corvallis Manor the peace of mind they deserved. No longer would they have to worry about leaks or water damage; they could focus on providing top-notch care to their residents, knowing their facility was in good hands.
For us at Flat Roof LLC, this project was more than just another job. It was an opportunity to showcase our expertise, our commitment to quality, and our unwavering dedication to our clients. We take great pride in our work, and we know that every roof we install has a direct impact on the lives of those who live and work beneath it.
If you're in need of a flat roofing solution, whether you're in Portland, Vancouver, or anywhere in between, give us a call at Flat Roof LLC. We'll be there to lend a helping hand, and to show you firsthand what sets us apart. Because at the end of the day, your roof is more than just a barrier against the elements—it's a promise of safety, security, and peace of mind. And that's a promise we take very seriously.