Cost-Effective TPO Overlay Replaces Aging Built-Up Roof in Amarillo, TX

Core Commercial Roofing recently completed a value-driven roofing project in Amarillo, Texas, delivering a modern, energy-efficient system to replace an aging built-up roof. The client was experiencing persistent leaks and declining roof performance but needed a solution that would balance durability with budget-conscious planning.

Initial Inspection and Roof Evaluation

The original system was a traditional built-up roof (BUR) with a gravel surface. While BUR systems are known for their longevity, this roof had reached the end of its service life, with signs of cracking, gravel loss, and ponding in several areas. Our team performed a thorough inspection and core sampling, confirming the presence of just a single layer beneath the gravel.

This key detail opened the door to more flexible repair options. Because there was only one roofing layer in place, we were able to present the client with two solutions: a full tear-off or a cost-effective overlay. After reviewing the pros and cons, the client opted for the overlay to stay within budget while still achieving long-term performance.

Overlay System Design and Execution

We began the overlay process by removing the loose gravel and preparing the surface for new materials. From there, we installed 1.5 inches of polyisocyanurate insulation, improving the roof’s R-value and helping reduce energy costs. In areas with drainage issues, we introduced tapered insulation to promote better water runoff and prevent future ponding—one of the primary causes of premature membrane failure.

For the new membrane, we applied a fully adhered 60 mil TPO system. TPO (thermoplastic polyolefin) is known for its excellent weatherability, UV resistance, and long-term durability. The fully adhered method provides a tight, secure bond that resists wind uplift—an important consideration in the often harsh West Texas climate.

Results: A 20-Year Roof System Without the Costly Tear-Off

Thanks to detailed inspection and smart system design, we helped the Amarillo client avoid the costs of a full tear-off and unnecessary code upgrades. The final system is not only energy-efficient and leak-resistant but also comes with a 20-year warranty, ensuring peace of mind for years to come. This project is a great example of how thoughtful engineering and clear communication can deliver a high-quality result that aligns with both performance expectations and budget constraints.