Built-up Roofing System (BUR) Explained

Don’t invest your resources in an inadequate roofing system for your commercial property. Uncovering the benefits and properties of a built-up roofing system can help you make informed decisions when installing a new roof or replacing your existing roofing system.

atlantacommercialroofingcontractors.com gathered the most helpful information about built-up roofing, its installation process, warranty, associated costs, frequently asked questions, and potential problems with built-up roofing systems.

Built-up Roofing – Production Process & Properties

Built-up roofing systems, referred to as BUR, have been in use in the U.S. for over a century. This roofing system is also known as a “tar and gravel” roof. BUR systems are typically composed of alternating layers of bitumen and reinforcing materials that create a membrane.

This roofing system gains its waterproofing and durability from its layered structure, consisting of a “built-up” or layered combination of components, including:

1. Substrate or Decking
2. Roof Insulation
3. Roofing Asphalt
4. Venting Base Sheet (Cover Board) with Roofing Asphalt
5. Ply Sheet with Roofing Asphalt
6. Slag or Gravel in Asphalt or a Modified Bitumen Cap

Note: When a modified bitumen membrane is used to cap a BUR system, this combination is referred to as a “hybrid” system.

Roofing asphalt (bitumen) commonly used in BUR systems includes:

Asphalt – Asphalt (a petroleum product refined from crude oil) requires heating before application with a mop or spreader

Coal Tar – Coal tar (derived from the distillation of coal) also requires heating before application with a mop or spreader

Cold-Applied Adhesives – These adhesives are solvent-based asphalts that don’t require heating prior to application

Surfacings used on BUR systems may be (or a combination of):

Aggregate – Gravel, slag, crushed stone, and/or mineral granules are common aggregates

Cap Sheets – Commonly made with glass-fiber or mineral surfacing

Asphalt – Hot Asphalt spread or mopped over the entire surface

Alternative Coatings – Aluminum and elastomeric coatings are commonly applied as surfacing for BUR systems

Benefits of Built-up Roofing

In use for over a century in the U.S., properly installed BUR systems provide the following benefits:

• Well-installed, a BUR system can last more than 30 years
• Provides excellent waterproofing protection
• Creates a continuous sealed surface
• Seams are very well sealed (in some cases, many times over)
• Provides exceptional UV protection
• Once installed, the system is extremely low-maintenance
• Excellent impact resistance
• Excellent fire resistance

Along with these benefits is traction. Often overlooked, if your roof has foot traffic, a BUR system may be ideal due to gravel providing an excellent grip. This becomes evident during severe weather.

Built-up Roofing Installation and Warranty

The installation of your built-up roofing system, when properly installed, is a moderately fast and non-intrusive process.

A built-up roofing system can be installed using hot asphalt or cold adhesives. A standard built-up roof system is a multiple layered system applied in such a way that creates a seamless roof. The following can influence the end result of the roofing system’s installation:

• Proper roof slope for efficient draining
• Correct installation and fastening of insulation
• Correct application of cold adhesives when used in place of hot asphalt
• Proper placement and overlapping of material
• Drip edge seamlessly connected around the perimeter of the roof

In addition to high-quality installation, a warranty is valuable when the installation or components of your roof fail. There are two types of warranties to consider when installing or replacing this or any other roofing system:

Contractor’s Warranty – This warranty covers the workmanship and installation of your roofing system by the contractor. The contractor guarantees their work for a set period (3, 5, 10-year period, etc.), or for the lifetime of the roofing system. A contractor’s warranty should include the following:

• A list of all covered items
• Actions or events that may void the warranty
• When/If the warranty expires

The above installation and warranty information underscore the absolute necessity to thoroughly vet contractors before starting a roofing installation or replacement.

Note: There is no established industry standard for the duration of a contractor’s workmanship warranty.

Manufacturer’s Warranty – This warranty covers defects in the roofing material used in your roofing system. Once installed, your contractor should provide you with manufacturer’s warranty certificates.

An example of material failure would be premature alligatoring (small cracks in the roofing surface from shrinkage). Unless it is determined to result from poor or improper installation, a claim can be leveraged against the manufacturer’s warranty.

Built-up Roofing Cost

Collecting estimates for a roofing system can be a tedious experience. There is often a significant disparity from one quote to the next, which reinforces the necessity to collect at least three bids from three reputable roofing contractors.

Prices for installing a built-up roof system may vary with the size/complexity of the roof, time of year, material brand and quality, method of installation, and the amount of labor required taken into consideration. You can expect to see pricing in the following ranges:

Tear-off – Unless your new roof is installed over your current roof, the old one will be removed.

This process can range between $100 and $200 per square (1 square = 100 square feet).

Tip: If this cost gets bundled in material and installation pricing. Request that it be detailed separately in your estimate(s).

BUR Material – will fall between $100 and $175 per square

BUR Installation (Labor) – can range from $300 to $525 per square

Maintenance Contract – Commercial roofing maintenance program prices vary from contractor to contractor

Using the price ranges above, you can expect to see bids, including tear-off, material, and installation for a 1,000 square foot roof between $5,000 and $9,000.

Consumer Tip: In the roofing industry, installations are typically more expensive in late spring and summer months. If possible, schedule your installation for the off-season (early spring and fall).

Disclaimer: The above pricing is in no way intended to represent actual bid values and only serves as an estimated market price range.

Built-up Roofing Problems

With new materials, installation methods, and technology, BUR systems are becoming less popular. That said, a built-up roofing system may still be the best option for your commercial building. Before making any decision, consider the following potential problems sometimes associated with a BUR system:

• High wind may cause rocks or gravel to be blown off the roof (potentially damaging nearby structures or persons)
• While leaks are easily repaired, finding them may be a laborious and costly process
• This roofing system is heavy in comparison to others. Your commercial roof load should be verified before installing a BUR system
• BUR installation is slower than that of other less complex roofing systems. Increased labor costs can make BUR systems more expensive

You must do your research to see if the pros outweigh the cons of this or any other roofing system. You can check out and compare the alternative options to a built-up roof system to find something better suited for your property’s needs.

People Also Ask

Can built-up roofs be repaired?

Yes. BUR roofing systems are easily and reliably repaired.

How long do built-up roofs last?

A well-installed and maintained built-up roofing system can exceed a 30-year lifespan.

Can built-up roofs handle foot traffic?

Yes. Due to the gravel or slag used in the roof’s finishing, BUR systems are slip-resistant, even in severe weather.

Built-up Roofing Information Revealed

In this article, you discovered essential information on the definition, installation, cost, warranty, and potential problems with built-up roofing systems.

Knowing how BUR systems are installed and maintained will help you make informed decisions on a roofing system for your commercial property.

Allowing yourself to be duped into an inadequate roofing system by an unprofessional roofing company can have very costly repercussions when the roof fails.

Sources:
asphaltroofing.org/bur-multi-ply-built-up-roofing/
everybodyneedsaroof.com/built-up-roof-BUR-membranes
homeadvisor.com/cost/roofing/flat-roof/
porch.com/project-cost/cost-to-install-built-up-roofing

The post Built-up Roofing System (BUR) Explained appeared first on atlantacommercialroofingcontractors.com

Commercial Roof Replacement

Avoid unexpected, expensive surprises when you replace your worn out commercial roof. By knowing the variable costs in a commercial roofing system replacement, you can ask the right questions to get a more accurate idea of the project cost.

atlantacommercialroofingcontractors.com gathered information about commercial roof replacement, what aspects of the project are variable in cost, what you can expect to spend on a new roofing system, and some of the available commercial roofing types.

Commercial Roofing System Replacement

The replacement of a commercial roofing system is a rare event for building owners and managers. When a roof is installed and maintained correctly, it can last for decades before needing replacement.

The following information will help you reach an informed decision about how to project roof replacement cost variables, and which type of roofing system to install:

Commercial Roof Accessibility

When replacing your commercial roof, access to your property and the roof can impact project costs as much as the roof type. Consider the following:

Commercial Building Height – Roof replacement for a 2-story commercial building will be much less costly than a 10-story commercial building. This is due, in part, to the need for cranes to remove old roofing material and lift new material to the work area.

Access to Building Property – Property access also has an impact on the project. The ability to freely move equipment to the property near the building will influence the logistics and project cost.

Material Storage Areas – Material storage is also a determining factor. Large “lay down” areas near the building facilitate the logistics of the roofing project and can lower its cost.

Building Occupant Safety – Building occupancy can pose a series of challenges to the roofing project. The safety and productivity of the building’s occupants must be considered at all times. If this requires roof replacement activities to occur after regular business hours, additional costs will likely be added to the project.

The easier it is to access your roof, execute the removal of the old roof, and install the new commercial roofing system, the less costly the project will be.

Commercial Roof Substrate Condition

Roof replacement costs can be heavily influenced by the condition of the substrate material. A commercial roof substrate may be composed of:

• A concrete, wood, or metal deck
• Plywood or cover board
• Insulation

Damages to the substrate must be repaired before roof replacement. This cost is a variable, as even the most experienced roofers with the best detection technology may not identify substrate damages until the old roofing materials are removed.

Local, Regional, and State Commercial Roofing Code Requirements

The location of your commercial building may make your roofing system subject to code requirements, including more robust fasteners at more frequent intervals, insulation, substrate, ventilation, and/or slope requirements.

An example of this would be commercial structures along the coast of Florida. Codes in these areas require commercial roofing systems to be designed to withstand higher wind loads. For these roofing systems, more durable fasteners at closer intervals would be required, increasing the cost of the roof replacement project.

Commercial Roof Load-Bearing Capacity

Another crucial factor in determining the cost of replacing your commercial roofing system is the calculation of its dead, live, and transient load capacity.

Calculating your roof load capacity is one of, if not the most crucial aspect when determining the construct of the roof’s substrate and selection of a roofing system. Your roof must be able to support its projected dead load (HVAC units, ducts, vents, exhaust units, etc.), live load (installers, repairmen, and technicians), and transient load (rain, wind, and snow).

Read more about commercial roof loads at atlantacommercialroofingcontractors.com/what-is-commercial-roof-load-why-you-need-to-know/

Commercial Roofing Types

No two roofs are the same. Thus, there are several commercial roofing systems to choose from. The following are some of the more popular commercial roofing types, installation information, and typical price range:

TPO, PVC, and EPDM Single-Ply Membrane Systems Can Cost from $3.50 to $8 per square foot

TPO, PVC, and EPDM are all known as single-ply roofing systems, they require fewer installation steps and are installed with a straightforward process:

• The old roofing system is removed
• The substrate is cleared of anything that may damage the selected membrane
• The membrane is rolled out onto the roof
• The membrane is then adhered to the roof using tape, glue, or heat (for thermoplastic material)
• The membrane is also adhered to itself where its edges overlap
• Protrusions are sealed

The time it takes to install a membrane, or single-ply roofing system also depends on the width of the membrane. The wider it is, the fewer seams there are to seal in the roofing system, which also leaves fewer opportunities for leaks and eventual substrate damage.

A BUR/Asphalt System Can Cost from $5 to $9 per square foot

Built-up roofing systems are among the oldest in modern times. BUR systems are durable and effective at resisting leaks while repelling water. The installation process occurs in the following steps:

• The old roofing system is removed
• Base sheets are laid down and attached to the roofing deck
• Felt is then glued to the base sheets using an adhesive, concrete, asphalt, or tar
• Gravel or cap sheets are installed over the felt
• A top layer of asphalt completes the installation

A BUR system creates a robust roof, able to keep severe weather and the elements from entering the building it protects.

A Metal Roofing System Can Cost from $5 to $14 per square foot

One of the most long-lived roofing options (forty + years), metal roofing is also one of the more expensive options. The following details how a metal roofing system is installed:

• The existing roof is removed
• The roof deck is built/prepped (framework and insulation installation)
• The flashing and eaves are installed
• Metal panels are laid out and fastened to the roof deck (fastening depends on which material the panels are composed of; aluminum, copper, steel, etc.)

Metal roofing comes in panels or steel shingles. Steel shingles are installed in the same manner as slate, clay, or concrete shingles.

A Modified Bitumen System Can Cost from $4 to $8 per square foot

Modified bitumen is a result of the evolution of asphalt roofing. It is a form of membrane flat roofing. The system is durable and can sustain substantial foot traffic without wear. The following is the installation processes of a “torch-down” modified bitumen roofing system:

• The existing roof is removed
• The substrate is cleared of any debris
• Heavy roofing felt is rolled out and nailed down
• Flashings and primer are installed
• The first sheet is rolled out along the edge of the roof for trimming and fitting
• The sheet is then rolled back up
• A torch is used to slightly melt the bitumen as the first sheet is rolled back out
• Overlapping sheets are then applied in the same manner until the roof is covered and sealed

Before selecting modified bitumen, verify that the existing substrate is compatible. Improper adhesion can lead to leaks and likely failure of the new modified bitumen system.

Disclaimer: The preceding price ranges are for comparative purposes only and should not be considered a part of any bid or quote for roofing installation, repair, or replacement.

Replacing Your Commercial Roofing System

In this article, you discovered information about replacing a commercial roofing system, the variables involved in calculating the cost, and commercial roofing types with their price ranges.

By knowing what to look for in a commercial roofing replacement estimate, you can avoid surprises by asking informed questions about installation variables.

When you choose to rely solely on a contractor’s bid or estimate, you may be in for a surprise when unforeseen damages and difficulties cause your roofing project to go quickly over budget.

Sources:
asphaltroofing.org/bur-multi-ply-built-up-roofing/
roofcalc.org/metal-roofing-prices/
nrc.gov/docs/ML1214/ML12146A122.pdf

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Pros and Cons for 3 Types of Commercial Roofing Systems

Avoid investing your money in the wrong roofing system. Each roofing system has advantages and disadvantages you should be aware of before making this capital investment.

atlantacommercialroofingcontractors.com gathered detailed information about three of the common commercial roofing systems, and their benefits and disadvantages.

Metal Roofing System Pros and Cons

Metal roofing systems are built to last, and depending on your region and property type, could be the only roofing system your commercial building may ever need. Here are some of the pros and cons to consider before committing to a metal roof.

Metal roofing system pros:

Longevity – Correctly installed and maintained, metal roofing can last as long as the building it covers (70 years or more).

Weather Resistant – Metal roofing It is highly resistant to rainwater, rot, mold, mildew, and can withstand immense pressure from accumulated snowfall.

Product Warranty – While warranties may vary, some companies will cover a metal roof installation for up to 50 years.

Fire Resistant – Metal roofing materials are noncombustible and resist fire.

Some metal roofing cons include:

Cost – Probably the most significant disadvantage, a metal roofing system can cost anywhere from $900 – $1,200 per 100 sq. feet.*

When the durability and longevity of metal roofing are factored in, the investment is more than justified. As previously stated, a properly installed and maintained metal roofing system can last as long as the structure below it.

Denting – When the necessity arises to service chimneys, satellite dishes, HVAC units, or generators, the serviceman or technician may dent your roof.

Likewise, if the gauge (thickness) of the roofing is too low in a region prone to hail storms, severe denting can occur during violent hail storms.

Noise – Metal roofing systems without sufficient insulation can get loud during rain or hail storms.

If you’re leaning towards a metal roof, read Metal Roofing Advantages and Disadvantages for a more in-depth article.

Built-Up Roofing System Pros and Cons

For more than a century, built-up roofing (BUR) systems have been a popular choice in the U.S. for commercial roofing systems.

This system is comprised of alternating layers of tar or asphalt and support materials layered on the roof, with the final one consisting of stone or gravel.

Built-up roofing system pros:

Longevity – A BUR system can last 30 to 40 years when properly installed and maintained.

Waterproof – There are no joints or seams; the roofing system is one continuous surface.

Low-Maintenance – After installation, minimal attention and servicing are required, as BUR systems are installed in large sheets with a low profile as compared to other roofing systems.

Cost – Installation and material costs can range between $500 to $800 per 100 sq. feet* or more depending on the number of layers and materials you choose.

UV Protection – BUR systems provide excellent ultra-violet protection, which reduces roof temperatures and prevents extreme temperature fluctuations within the building. UV protection also prevents the drying out and break down of roofing system materials.

Some built-up roofing cons include:

Safety – During installation, hazardous fumes and vapors are present.

Weight – BUR systems add significant weight to a building’s structure.

Learn more about commercial roof load-bearing capacity by reading atlantacommercialroofingcontractors.com/what-is-commercial-roof-load-why-you-need-to-know/

TPO Roofing System Pros and Cons

Thermoplastic Polyolefin (TPO) is a single-ply roofing system fully adhered and mechanically attached or ballasted to a roof.

TPO roofing system pros:

Longevity – TPO roofing has a (current) life expectancy of about 30 years. However, this roofing system has only been available for 30 years, and with significant improvements over the decades, TPO may last much longer.

Wind Resistant – When properly installed, TPO roofing systems receive high wind ratings.

Installation – TPO roofing system installation, when completed by an experienced roofing company, is fast, clean, and practically nonintrusive.

TPO roofing cons include:

Pooling Water – When the roof slope is too low, water may pool and cause an acceleration of the material’s degradation.

Cost – Installation and material costs can range between $600 to $1,400 per 100 sq. feet* or more depending on tear-off costs and selected materials.

Seam Separation – Poor seam welding can result in seam separation, allowing water into the structure.

Read more about TPO roofing systems at atlantacommercialroofingcontractors.com/tpo-roofing-system-explained/

Commercial Roofing Types

Before committing thousands of dollars for a new roof, take the time to familiarize yourself with different types of available roofing systems for your building.

In this article, you discovered information about 3 commercial roofing system options, their durability, price ranges, and other essential pros and cons.

Avoid making a poor decision when selecting a roofing system for your commercial building. Learn as much as you can about available commercial roofing systems in your area, and your local roofers,

*Costs related to roofing materials, tear-offs, and installations mentioned in this article are approximations NOT QUOTES. Visit atlantacommercialroofingcontractors.com for further information.

Sources:
everybodyneedsaroof.com/thermoplastic-membranes
asphaltroofing.org/bur-multi-ply-built-up-roofing/
cchrc.org/sites/default/files/docs/metal_roofing.pdf

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