EPDM warehouse

The warehouse roof had reached the end of practical service: seams opening at field splices, ballast shifting off low spots, and chronic ponding within ten feet of two internal drains. Operations could not afford a long shutdown, so we sequenced work in halves with temporary rain covers at night.

We removed saturated insulation in the worst bays only, re-sloped slightly with new tapered ISO toward the drains, and installed a new ballasted EPDM field with factory-tape splices and liquid flash at odd angles.

Risk items we addressed

• Crushed perlite under old ballast — replaced in strips
• Scupper overflow height vs new insulation build-up
• Skylight curbs with prior amateur caulk jobs
• OSHA tie-off planning for forklift traffic below

Crew sequence

1. Set protection: Interior plastic under drains; barricade forklift lanes.
2. Strip west half: Remove ballast, membrane, wet insulation; deck repair.
3. Rebuild: ISO + cover board + EPDM; ballast to design weight.
4. Flip east: Repeat; tie center splice last with manufacturer rep on site.

Cost drivers (reference)

Percentages shift on every building; this table is illustrative of this warehouse after bid leveling — not a universal rule.