Project 1853: Maintenance Shop - Dumas, TX

Core Commercial recently completed a comprehensive design-build roofing retrofit for the Texas Department of Transportation at their Dumas, TX Maintenance Shop. The existing roof, a standing seam metal system, had sustained substantial wind damage. After thorough evaluation, our team and engineers made a strategic decision: rather than tear off the existing metal panels, we would repurpose them as a structural deck and install a high-performance TPO retrofit system above.

Retrofit Strategy: From Metal to Modern

The key to this retrofit lay in transforming the ribbed profile of the standing seam metal into a solid, insulatable substrate. To achieve this, we began by installing flute fill, custom-cut rigid insulation designed to precisely fit into the fluted valleys of the metal roofing panels. Using a specialized flute-filling tool, we accurately measured the dimensions and spacing of the existing panel ribs, ensuring each piece of flute fill was perfectly fitted. This tool is critical in retrofit applications, allowing for a snug, secure fit that prevents insulation gaps and thermal bridging.

The flute fill was loose-laid directly into the metal panel valleys, creating a level surface across the roof. Over this, we installed a continuous layer of high-density polyiso insulation. This high-compression board added both structural integrity and thermal value to the assembly. We fastened the polyiso directly into the structural purlins beneath the metal panels using long fasteners engineered for this type of retrofit deck.

Tapered System and Drainage Design

Drainage was a significant consideration for this facility. As part of the in-house design-build process, Core Commercial created a tapered insulation system tailored to the existing slope conditions. This system was carefully laid out to ensure positive drainage across the entire roof, directing water toward newly installed collector boxes and downspouts. The improved slope eliminates ponding water and reduces long-term wear on the membrane.

TPO Installation and Warranty Protection

With the insulation securely in place, we fully adhered a 60-mil TPO membrane across the entire surface. This robust, energy-efficient membrane provides excellent resistance to UV exposure, punctures, and weathering, an ideal choice for West Texas conditions.

This project was not just a retrofit; it was a fully integrated design-build collaboration. Core Commercial engineers worked hard to create a roofing solution that met all structural, thermal, and drainage requirements. All drawings and plans were developed internally and submitted for approval as part of the design-build delivery method, streamlining coordination and ensuring precision from concept to completion. The finished system is protected by a 20-year No Dollar Limit (NDL) warranty, guaranteeing long-term performance and value for the State of Texas.

The finished system is protected by a 20-year No Dollar Limit (NDL) warranty, guaranteeing
long-term performance and value for the State of Texas.