Home / Project / Flat Roof Repair in Plainfield, NJ – Torch-Down to TPO Replacement
Torch-down roofing removal
Completed TPO roof in Plainfield

Flat Roof Repair in Plainfield, NJ – Torch-Down to TPO Replacement

At Yukor Construction, we repaired a leaking flat roof on a commercial property in Plainfield, NJ. The existing torch-down roofing had worn out to the point that it needed to come off completely.

We stripped the old roofing, prepared the underlying deck, and installed a new TPO membrane. The job covered the main roof surface, wall flashing, perimeter details, and the existing roof drain. This project is one example of our roof repair services in New Jersey.

Why We Chose TPO for This Flat Roof Replacement

This property called for a full flat roof replacement. Tearing off the existing roofing gave us access to the wood deck, so we could fix damaged areas before installing the new waterproofing system.

We went with TPO, a thermoplastic polyolefin roofing membrane built for low-slope applications. Its seams are welded with hot air, which creates watertight connections. And the white surface reflects sunlight, so less heat builds up on the roof.

Our TPO and EPDM flat roofing services include membrane installation, repairs, and replacement. For this project, TPO provided a practical way to waterproof the roof and its transitions to the walls, perimeter, and drainage outlet.

Torch-Down Removal and TPO Roof Installation Steps

1

Removing the existing torch-down roofing

We used hand tools to pry the old bituminous roofing off the wood deck, rolling up the removed sections for disposal as we moved along the roof. Both the main surface and the flashing areas along the building were cleared.

2

Preparing the wood deck

With the old roofing gone, we could get to the deck panels and their joints. In one damaged area, we cut out a deteriorated section of decking, exposing the wood framing below. Then we cleared loose roofing residue and debris before moving on to the next layers.

Damaged wood roof decking
3

Installing roofing boards

We cut rigid roofing boards to fit the work area and secured them to the wood deck with roofing screws and fastening plates. The plates spread the clamping force across a wider area of each board. We also cut an opening around the existing roof drain.

4

Preparing the roof drain connection

Before laying the membrane, we applied a sealing compound around the drain's seating area, keeping the drainage opening accessible the whole time.

Roofing boards with fastening plates
5

Positioning and securing the TPO membrane

We rolled out the white membrane along the roof and lined it up with the building wall and outer edge. Next, we applied strips of adhesive to the underside of a folded-back section to bond it to the prepared surface. The outer edge also has mechanical fasteners with fastening plates.

Roof drain preparation
6

Welding the membrane joints

Handheld hot-air welding equipment joined the membrane sections. As we heated each joint, a pressure roller pressed the surfaces into firm contact to form the welded seam.

7

Completing wall flashing and perimeter details

We ran the membrane up the adjoining vertical surfaces and fitted metal flashing over the upper edge of the wall transition. Then we finished the outside perimeter, roof ends, and corners.

TPO roofing membrane installation
8

Cleaning up the site

Once installation was complete, we hauled away the old roofing, material offcuts, and all construction debris, and cleared our tools and equipment from the work area.

frrp7

Commercial Flat Roofing Challenges on This Plainfield Project

  • Limited space along the building
    The long, narrow roof took careful planning to place and move materials throughout the job.
  • Deck damage beneath the old roofing
    Removal uncovered deteriorated wood decking, which we had to deal with before the new roof could go on.
  • A long connection to the brick facade
    This transition called for precise membrane fitting and careful detailing at the upper edge of the flashing.
  • Several different roof details
    The work spanned the main roof surface, vertical transitions, exposed edges, corners, and a roof drain.

Results of the TPO Roof Replacement

A new TPO roofing system replaced the worn torch-down covering. We rebuilt the waterproofing layer across the work area and completed its connections to the surrounding structures.

With the deck prepared and the seams and flashing finished, the roof has a sound foundation for long-term performance. Periodic inspections and a clear roof drain will keep the system in good shape and catch maintenance needs early.

Flat Roof Replacement Cost and Timeline in Plainfield, NJ

This price covers the work completed at this property. We estimate other projects individually based on roof size, deck condition, site access, and installation requirements.
Days
0
$$$
0

Need Flat Roof Repair in Plainfield, NJ?

Contact Yukor Construction for a free estimate. Our roofers in Plainfield will assess your roof, tell you if it needs repair or replacement, and recommend a practical solution for your property.

CONTACT
Back to list
Older Torch-Down Flat Roof Repair with Silicone Roof Coating in Englishtown, NJ

Related projects