New TPO roof system on Montgomery, AL church

Montgomery, AL

Alabama's Local Roofer

Since 1982

Mobile, AL

TPO Roof System installed on historic church in downtown Montgomery, AL

In the summer of 2017, we installed a new TPO roof on a historic church in downtown Montgomery, AL. Built in 1925, St. John the Baptist Catholic church has had several roof replacements over the nearly 100 years it’s been in Montgomery, AL. Despite the multiple roof replacements, the roof still had several chronic leaks. However, like a lot of older roofs, the roof was never actually replaced, but layers of new roofing were installed on top of the old roofs. In roofing jargon this is called a layover, and not something that we recommend with historic properties. Historic roofs, anything over 60 years old, usually will have decking issues that need to be addressed and/or cannot support the weight of multiple roof systems. The chronic roof leaks were isolated towards drainage areas, but the current top layer of roofing was near the end of it’s functioning life, so we recommended a total roof replacement.

We did a core sample of the roof to determine how many layers were actually on the roof. We found four distinguishable layers of roofing. The bottom layer, the layer attached directly to the wood deck substrate, was the the most interesting. It was 90 year-old  stamped metal, buried underneath (3) layers of roofing. Once we removed all layers of roofing, including the stamped metal, we found a beautiful wood. My favorite part of replacing historical roof is seeing the wood deck after removing all the old roofing material. The wood has been unseen and untouched for years. And even though a lot of the wood usually needs to be replaced, a good portion of most older roofs keep its original structural integrity. The framing is always made of true 2″x’s and the old growth pine lumber takes longer to rot, even when moisture is present. We removed all layers of roofing down to the original wood deck. Despite the chronic roof leaks and age of the roof, the decking was in fairly good condition. We replaced a couple hundred linear of 1″x8″ board sheathing and cancelled (2) vents that were no longer in use. We’ve learned from years of experience (sometimes the hard way) that properly preparing a roof deck, especially on an roof, is one of the most important components to a new roof system. Once the deck was prepared we installed a synthetic moisture barrier over the entire roof. Then to provide a smooth substrate for the TPO, we installed 1″ insulation boards. The insulation boards were mechanically attached to the wood deck with screws and plates. When working on commercial roofs it’s important to place mechanical fasteners in a systematic and consistent way to protect against wind up lift. Each of the 4’x8′ insulation boards received no less than (6) fasteners. 

We used .60 mil GAF, bright white TPO. To minimize the number of seams in the roof we used 10’x100′ rolls of TPO. These wider rolls are harder to get on the roof and control, but once installed they r limit the number of seams on the roof. Roof leaks on commercial roofs usually happen at the seams or around obstructions. However. because TPO is heat welded, the seam becomes the strongest and thickest  part of the roof system. If seams are welded correctly they fuse together and form a monolithic sheet.  We mechanically attached all the TPO placing the fasteners every 6″ for superior wind uplift protection. We used a welding robot to heat weld all of the seams in the field of the roof and hand welders around the perimeters and obstructions. This roof system carriers a 20-year manufacturer warranty and a 5-year workmanship warranty. 

Copyright © 2017 Guyette Roofing and Construction LLC | All Right Reserved

Why Roof Pipe Collars Leak

Montgomery, AL

Alabama's Local Roofer

Since 1982

Mobile, AL

The overwhelming majority of residential roofs have at least 1, or several, vent pipes protruding through the roof. These vent pipes serve as conduits to allow gas and/or air to escape through the roof. The pipes, originating  in kitchens and bathrooms, transport the gas and/or air without having to be turned on or tended to. Because of this, and the fact that most of these pipes are located on the back side of residential roofs, most homeowners don’t think twice about these pipes sticking through their roof. So, they go unnoticed; unnoticed, until a roof leak develops. 

Undoubtedly, one of the most common types of roof leak are leaky roof pipes. The most common cause of a leaking vent pipe occurs at the collar surrounding the base of the pipe. The base of the vent is usually aluminum or galvanized steel, but the collar, or gasket, is usually made of rubber or plastic. The reason pipe penetrations leak is two-fold – #1, many pipes collars are not made to last as long as the shingles that surround them; #2, the roofers don’t understand how to properly shingle and seal a pipe collar. Any time an obstruction penetrates a roof, it’s imperative that the right material is used and that the roofers know how to properly roof around it. 

The most common types of roof collars are made of of either plastic, lead or galvanized steel. Plastic pipe collars, especially in the Alabama heat tend to dry rot and break-down prematurely. Plastic pipe collars are the cheapest for the roofer (weather he passes the savings to the homeowner is uncertain), thus are the most common collar used around pipe penetrations on shingle roofs. A properly installed plastic pipe collar can last 10-15 years. However, since plastic is the cheapest material for a pipe collar, they tend to attract less than reputable roofers, which means workmanship is usually sub-standard causing the pipe collar to never reach its optimal lifespan. 

Lead pipe collars, if properly installed, are always a good choice. Lead is a durable yet pliable material in roof applications, hence the long-term use of lead pipe collars. But squirrels love to eat lead, and the state of Alabama has a lot of squirrels. When squirrels chew on the lead, it comprises the pipe collar creating leaks inside the house. Of course, if you don’t have squirrels that every climb on your roof, a lead pipe collar can be a good choice. 

In our experience, galvanized steel is the only viable, long-term solution to flashing around pipe penetrations. Galvanized steel is rot resistant, animals don’t bother it, and is paintable (painting pipes gives the roof a nice finished look). To avoid costly leaks and repairs, we use 1 of 2 kinds of pipe flashings on our residential shingle roofs. For our Standard Roof System, we use IPS Flashings with a galvanized base and flexible elastomeric collar. These collars come in 2 sizes (3/1″ of 4/1″) and are made to custom fit each pipe penetration. For our Ultimate Roof System, we use the The Ultimate Pipe Flashing System with a wider, marine grade stainless steel base and silicone collar. These collars come in 5 sizes (1 1/4″, 1 1/2″, 2″, 3″, and 4″). The Ultimate Pipe Collar provides a lifetime precision watertight seal with its ultra-pure silicone collar and PVC compression boot. All pipes collars installed on our roof systems are installed with a Storm Guard “target” under the shingles and fastened to the roof deck with heavy gauge metal screws. 

Leaks around pipes collars often go undetected. The roof leak is usually never a major one but it does allow rain water to enter the attic space. If the attic is properly insulated, the insulation will absorb the water, completely drying before the next rain. This cycle will go on-and-on until the the plywood decking surrounding the pipe collar completely rots. However, these small leaks work like compound interest, if you leave it alone long enough, the monetary value will be huge. 

Copyright © 2017 Guyette Roofing and Construction LLC | All Right Reserved

Highest Roof In Alabama

Montgomery, AL

Alabama's Local Roofer

Since 1982

Mobile, AL

Highest Roof in Alabama gets New Roof System

This 1950’s transmitter building at the top of Mount Cheaha in Mt. Cheaha State Park had (4) layers of old roofing on top of a concrete substrate. It had been leaking for years and was in desperate need of a new roof system. The top layer of the existing roof system had piles of gravel creating an uneven surface across the entire roof. Because the roof was originally flat and the surface was uneven, water was not properly draining. So, we removed the gravel and all old roofing material down to the concrete deck. Once all the old roofing was removed and the concrete deck was properly cleaned, we installed a layer of 1/8″ tapered insulation to give the roof a positive slope. We used GAF’s 2-part adhesive to adhere the insulation to the concrete deck. Due to extreme elements and chronic patch type repairs, the 70-year roof deck had lots of irregularities. The 2-part adhesive, which is applied in a bead-like form, allowed us to level out much of the concrete deck. Then, we fully adhered .80 mil GAF EverGuard TPO. Because it provides better wind uplift protection than other systems, a fully adhered TPO system is best for high wind zone areas. All seams were heat welded with hand held welders and welding robots. 

Copyright © 2017 Guyette Roofing and Construction LLC | All Right Reserved

TPO Recover on Montgomery, Alabama Commercial Roof

Montgomery, AL

Alabama's Local Roofer

Since 1982

Mobile, AL

TPO Recover Project in Montgomery, AL

Every building is different and has unique requirements when it comes to choosing the right roof system. Commercial roofs, because of their larger surface areas, roof obstructions (HVAC equipment, pipes and ventilation), and drainage concerns, require careful attention when determining the proper roof system. However, one of the biggest concerns with commercial roofing projects, is getting the job done in a timely, safe manner while not jeopardizing the business activity of the tenants below.  This particular commercial roof had (3) fully operational stores below. Each store had customers coming in and out of the building on a daily basis. Also, each store was experiencing roof leaks with every rain. And summer times in Alabama, are unforgiving to comprised roof systems. 

With a chance of rain every afternoon for the next (4) months (typical for Alabama summers), we had to install a new roof system fast, yet efficient to not comprise quality control. This roof had a layer of modified bitumen on top of a plywood deck substrate. With 90% of the roof deck in solid, dry condition, we determine that leaving the existing (1) layer of roofing on was the best option for this particular roof. This is what’s called a “recover” option and does not effect manufacturer warranties as long their is only (1) existing layer. 

After an inspection of the underside of the roof through the attic, we noticed several areas along the perimeter of the roof that appeared to be rotted. The roof had poor drainage in this area, causing chronic issues and plywood to rot over the years. We surgically removed this comprised section of the roof, and change (32) 4’x8′ sheets of CDX plywood. During this phase of the project we also eliminated (11) obsolete pipe penetrations. Older commercial roofs almost always have roof penetrations that have been canceled from the inside or are no longer operational. It’s always best to eliminate this obstructions, that tend to be leak prone, during a roof replacement project. We added structural support and decked over this places. Once all rotted plywood was replaced and obsolete pipe penetrations filled, we started installing the new material. 

We mechanically attached a 1/2″ layer of cover board over the entire roof. The cover board provides a smooth, even substrate for the single-ply membrane, or TPO. Next we installed GAF’s .60 mil EverGuard TPO. We used a bright white TPO for energy efficiency. To reduce the number of seams in the roof, we used 10’x100′ rolls of TPO. All the seams were heat welded by a hand held welder or a welding robot. For quality control, we probe the seams several times to check for any voids or cold welds. Finally, we installed custom eave drip flashing around the entire perimeter. We worked over time and through the weekend to complete this roof in (4) days. 

No business was lost during the 4 day project, and the owners of the building received a quality roof. 

Copyright © 2017 Guyette Roofing and Construction LLC | All Right Reserved