RockTenn Roof Replacement
Marion, NC
222,216 sq. ft. GAF TOPCOAT
54,480 sq. ft. GAF 60-mil EverGuard TPO
This TPO roofing and coating project gave RockTenn a durable, energy-efficient roofing solution for a large facility in North Carolina. The project combined TPO roofing on one section and roof coating on the remaining salvageable roof areas.
Why TPO Roofing and Coating Made Sense
RockTenn, a national packaging and corrugated products manufacturer was looking for an energy-efficient, long-term roofing solution for their 276,696 sq. ft., newly purchased facility in Marion, North Carolina. Preliminary inspections revealed numerous issues with a 54,480 sq. ft. section of the old roof, including abundant leaks, soaked insulation and the presence of a large amount of non-friable asbestos-containing material (ACM). The remaining 222,216 sq. ft. was salvageable but needed additional protection from the elements. A detailed inspection helped identify the best TPO roofing scope for the damaged section. The team also identified where roof coating could protect the rest of the facility.
The multi-faceted project included the tear off and disposal of the asbestos insulation on the badly damaged 54, 480 sq. ft. section in accordance with OSHA and EPA regulations. Because the renovated facility will be climate controlled, North American Roofing then mounted a 3-inch layer of polyisocyanurate (ISO) insulation before installing reflective, energy-efficient, GAF 60-mil EverGuard® thermoplastic polyolefin (TPO) roofing, complete with a 20-year, no dollar limit (NDL) warranty. The TPO and coating re-roof project was a great fit for RockTenn’s situation. The new TPO roof delivered reflectivity, durability, and long-term value. This TPO roofing system also supported the owner’s energy-efficiency goals.
Metal Roof Edge
We fitted 24-gauge metal roof edge around the roof perimeter and installed single-cleated coping around the parapet walls. To ensure proper drainage, we ran 22-gauge metal guttering, fitted with 24-gauge, heavy-duty downspouts. These edge details helped strengthen the full TPO roofing assembly. They also supported drainage and long-term roof performance.
TopCoat
On the remaining roof sections, we applied GAF’s TOPCOAT® elastomeric roofing membrane to seal and waterproof the standing seam metal. With high tensile strength and solar reflectivity, TOPCOAT® was the best solution for seamless protection over the existing metal roof. This roof coating strategy protected the existing metal roof without full replacement. It gave the owner a practical way to extend roof life and control costs.
Since RockTenn decided to install a new HVAC system at the same time, North American Roofing filled in existing voids from previous tenants and flashed in the new HVAC components and penetrations.
RockTenn wanted to replace the damaged roof section and protect the rest of the viable roofing. With a focus on energy efficiency, North America Roofing was able to offer a cost-effective dual solution that solved both problems. This TPO roofing and coating approach solved two different roofing problems in one project. It also shows how a TPO roof and commercial roof coating can work together on a large facility.
TPO Roofing and Coating Project Highlights
This project included 54,480 square feet of GAF 60-mil EverGuard TPO. It also included 222,216 square feet of GAF TOPCOAT. The team removed damaged materials, added new polyiso insulation, and installed a reflective TPO roof. The coating system sealed and protected the remaining metal roof.
What This TPO Roofing Project Shows
A large commercial facility may need more than one roofing strategy. TPO roofing can solve severe damage on one section. Roof coating can protect other sections that remain structurally sound. This project shows how owners can match the roofing solution to each roof area.
FAQ
What is TPO roofing?
TPO roofing is a single-ply membrane used on many commercial roofs. Owners choose it for reflectivity, durability, and strong long-term performance.
Why did this project use both TPO roofing and roof coating?
The damaged section needed full replacement with a new TPO roof. The remaining metal roof sections could stay in place and benefit from roof coating.
What type of TPO roof did North American Roofing install?
The team installed GAF 60-mil EverGuard TPO on the damaged roof section. The project also included new polyiso insulation.
What type of roof coating did the project use?
The project used GAF TOPCOAT on the salvageable metal roof sections. The coating helped seal and waterproof the existing roof.
Can TPO roofing improve energy efficiency?
Yes. Reflective TPO roofing can support energy-efficiency goals on commercial buildings. GAF also describes EverGuard TPO as highly reflective in white.
When does roof coating make sense instead of replacement?
Roof coating often makes sense when the roof remains structurally sound. It can add protection and help extend service life.
Need a smarter solution for a damaged commercial roof? North American Roofing helps owners evaluate each roof area, choose the right mix of TPO roofing and roof coating, and protect long-term building performance. Contact our team to schedule an inspection and discuss the best path for your facility. (800) 551-5602
