Hail Damage: Full Roof Replacement

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Project Information

  • ClientSmoky Hill
  • Category

Colorado is known for its breathtaking landscapes, but it is equally notorious for its severe weather. When devastating hail battered the Smoky Hill community, the Smoky Hill Church facility sustained severe damage to its expansive flat roof. Water intrusion and compromised structural integrity are significant risks for any commercial property after a massive storm, making a complete roof replacement the only viable solution.

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B&L Roofing stepped onto the scene to execute a comprehensive, multi-tiered roof replacement. Below is a step-by-step look at how our dedicated crew transformed a hail-damaged liability into a pristine, weather-tight fortress.

Phase 1: Mobilization and Staging

A project of this magnitude requires serious logistics before a single piece of old roofing is removed. Working on a massive commercial property means dealing with thousands of square feet of materials.

A massive mobile crane from Duffy Crane and Hauling arrives at the Smoky Hill Church parking lot to safely hoist heavy, palletized rigid insulation boards onto the roof.

 

Staging is critical for efficiency. Rolls of new white roofing membrane and insulation boards are carefully distributed across designated load-bearing zones to keep the workflow moving smoothly.

 

Phase 2: Tear-Off and Exposing the Deck

To ensure the new roof system performs flawlessly for decades, the damaged materials must be completely removed. We stripped the old roofing layers down to the bare structural deck, evaluating it for any hidden structural issues.

The tear-down phase in action. Here, the damaged roofing materials have been removed to expose the original dark, corrugated metal roof deck beneath.

 

Looking down a long structural channel. Removing the old roof creates a chaotic but necessary construction zone as debris is cleared away to make room for the new system.

 

Phase 3: Building the Foundation (Insulation and Cover Boards)

A modern commercial flat roof is an engineered system of layers. Over the exposed deck, we began the meticulous process of building up the insulation and cover boards. This multi-layered approach ensures optimal energy efficiency for the building and creates a robust, puncture-resistant substrate for the final membrane.

The first layer goes down: brown rigid insulation boards are laid over the corrugated metal deck and secured with white mechanical fastening plates.

 

Layering continues with a dark vapor barrier followed by rigid green-faced cover boards to build up the necessary thickness and thermal resistance.
A B&L Roofing crew member walks past a staged stack of dark grey rigid insulation boards ready for deployment across the mid-section of the roof.

 

A dense, tightly fitted layout of tan rigid insulation boards spans the roof deck, prepped and ready for the next phase of metallic framing and cover board installation.

 

Precision is key. A technician meticulously places dark cover boards tightly against the base of a beige louvered equipment screen to ensure a smooth, uniform substrate.

 

A close-up view of the mechanical fastening process. These round white plates and heavy-duty screws secure the insulation tightly to the roof deck beneath to prevent wind uplift.

 

Phase 4: Rolling Out the New Shield

With the foundation perfectly prepped, it was time to install the primary defense against the Colorado elements: a bright, highly reflective white single-ply roofing membrane.

The crew regroups on a completed section to coordinate the rollout of the remaining membrane layers.

 

Heavy rolls of the white single-ply roofing membrane sit in their protective factory wrapping, ready to be rolled out and heat-welded.

 

A great visual representation of the progress: the transition zone where the dark grey cover board meets the newly rolled bright white reflective membrane.

 

B&L technicians kneel to carefully align, secure, and detail the critical seam where the new white membrane overlaps the underlying layers.

Phase 5: Precision Detailing and Equipment Integration

A roof is only as good as its weakest seam. Commercial roofs are notoriously complex, cluttered with HVAC units, exhaust vents, and miles of gas lines and electrical conduits. Flashing and sealing around these penetrations require extreme attention to detail to prevent future leaks.

A worker custom-cuts membrane flashing to fit perfectly around the base of a large Carrier HVAC unit.

 

Navigating the obstacle course. Technicians perform intricate detail work around long pipe conduits and commercial exhaust fans.

 

Securing the base of shiny metal exhaust vents. Primer, adhesive, and custom flashing are utilized to make sure water cannot penetrate the edges.

 

Proper integration around structural supports. The white membrane is neatly flashed and sealed beneath the heavy steel I-beams supporting the louvered penthouse.

 

A lone worker in the distance kneels to perform final detail work along the perimeter parapet wall.

Phase 6: The Final Inspection

After weeks of hard work, removing tons of hail-damaged debris, and meticulously laying down a state-of-the-art roofing system, the final result speaks for itself. The Smoky Hill Church is now protected by a brilliant, seamless, and highly durable flat roof capable of withstanding the worst that Colorado weather has to offer.

A sweeping view of the finished surface cleanly integrating around a structural column, with the church parking lot below.

 

Clean, sharp lines where the pristine white membrane meets the fully flashed parapet walls.

 

A perfectly straight run of black conduit piping, elevated on protective support blocks, travels across the clear, debris-free roof.

 

The commercial utility zone. Multiple Carrier HVAC units sit flawlessly integrated into the bright white, energy-reflective surface.

 

The finished product overlooking the beautiful Colorado landscape. A watertight, highly efficient, and beautifully executed roof replacement by B&L Roofing.

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