Amarillo Headquarters Roof Rebuild Project

Existing Conditions

The original roof was a built-up asphalt system with a gravel surface, installed over a structural concrete deck. It consisted of a single roofing layer that had exceeded its service life. Beyond typical aging and weather exposure, the roof suffered from a lack of positive drainage, leading to ponding water and associated maintenance issues. Due to the concrete deck, conventional mechanically fastened systems were not an option. This required a specialty attachment method that would ensure strong adhesion without compromising the integrity of the structure.

System Design & Installation

To resolve drainage issues and provide a durable, long-term solution, Core Commercial Roofing implemented a multi-layered, fully adhered TPO roofing system engineered for performance and precision. 1. Concrete Deck Preparation & Attachment Because the substrate was a structural concrete deck, fasteners were not feasible. Instead, a two-part polyurethane foam adhesive was used to secure each layer. This method provides superior wind uplift resistance and avoids penetrations that could compromise the deck’s integrity. 2. Base Layer Insulation The first layer installed was 3.4 inches of flat polyisocyanurate insulation. This layer established a solid thermal barrier and base for the more complex tapered design to follow.

1. Concrete Deck Preparation & Attachment

Because the substrate was a structural concrete deck, fasteners were not feasible. Instead, a two-part polyurethane foam adhesive was used to secure each layer. This method provides superior wind uplift resistance and avoids penetrations that could compromise the deck’s integrity.

2. Base Layer Insulation

The first layer installed was 3.4 inches of flat polyisocyanurate insulation. This layer established a solid thermal barrier and base for the more complex tapered design to follow.

3. Full Tapered Insulation System

One of the standout features of this project was the installation of a full tapered insulation system using engineered polyiso. Rather than just correcting localized low spots, the entire roof was re-sloped to promote efficient drainage throughout. This custom tapered design involved precise elevation planning and layout, ensuring that water would be directed away from the roof surface and toward the perimeter drainage points.

The tapered polyiso not only resolved years of ponding issues but also improved the energy efficiency of the building by adding additional R-value where possible.

4. Cover Board

A half-inch DensDeck cover board was installed over the tapered insulation. This fiberglass-reinforced gypsum board adds fire resistance, enhances impact protection, and provides a stable substrate for membrane adhesion, particularly important in a high-performance, fully adhered system. 5. Membrane: Fully Adhered TPO The final waterproofing layer consisted of a fully adhered TPO (thermoplastic polyolefin) membrane. This system offers excellent resistance to UV, heat, and chemical exposure, making it a reliable choice for long-term performance in the harsh Texas climate. The membrane was carefully adhered across the entire roof surface, ensuring a monolithic seal.