Project Overview: Arlington TX Commercial Roof Repair & Replacement
When a commercial print shop in Arlington, Texas found itself facing a severely hail-damaged spray foam roof, the team at CSI Commercial Roofers stepped in with a comprehensive solution built for long-term performance and code compliance. The existing spray polyurethane foam (SPF) roof system had sustained extensive impact damage from a significant hail event — compromising its waterproofing integrity, insulation value, and structural viability. A full tear-off and re-roof was the only responsible path forward.
CSI’s experienced crews managed every phase of the project — from damage assessment and material coordination to permit compliance and final inspection — delivering a finished roofing system engineered to protect the facility and its operations for decades to come.
The Challenge: Replacing the old system with cost effective & energy efficient TPO
Spray foam roofing systems, while effective when properly maintained, are particularly vulnerable to large hail events. The hail strikes had pockmarked and fractured the foam surface across the entire roof plane, eliminating its reflective coating and exposing the underlying foam to UV degradation and moisture infiltration. The damage was widespread and severe enough that localized repairs were not a viable option — the entire roof assembly required removal.
Beyond the physical damage, the project also needed to satisfy updated City of Arlington building codes regarding insulation R-value thresholds for commercial structures — adding an additional layer of engineering and material planning to the scope of work.
Scope of Work: Repair & Replacement
1 Complete Removal of Existing Spray Foam Roof System
The severely hail-damaged SPF roof was fully torn off and disposed of, clearing the deck for a fresh, code-compliant assembly and allowing for a thorough inspection of the substrate below.
2 Deck Inspection & Preparation
With the old system removed, the roof deck was carefully inspected for any structural concerns, moisture intrusion, or fastener issues. Any compromised sections were addressed before new materials were installed to ensure a solid, sound foundation for the new assembly.
3 Installation of Two Layers of 2.2″ Polyisocyanurate (ISO) Insulation
To meet current City of Arlington energy code requirements, two layers of 2.2-inch polyiso rigid board insulation were installed in a staggered, offset pattern — eliminating thermal bridging at joints and maximizing the effective R-value of the insulation assembly. Polyiso delivers the highest R-value-per-inch of any rigid insulation, making it the ideal choice for code compliance without adding unnecessary roof system thickness.
4 Installation of Elevate 60 Mil TPO Membrane
The new primary waterproofing layer — an Elevate 60 mil thermoplastic polyolefin (TPO) membrane — was installed over the insulation system. At 60 mils thick, this robust single-ply membrane exceeds standard commercial roofing specifications, providing superior puncture resistance, UV reflectivity, and long-term weathering performance. TPO’s heat-welded seams create a monolithic, watertight surface that significantly outperforms adhesive-bonded alternatives.
5 Flashing, Terminations & Detail Work
All penetrations, perimeter edges, curbs, and transitions were carefully flashed and sealed using manufacturer-approved methods and materials — critical areas where roofing failures most commonly originate. Every detail was executed to Elevate’s strict installation standards, a prerequisite for warranty qualification.
6 Final Inspection & Warranty Registration
Upon project completion, the roof system was inspected and registered for a 20-Year No Dollar Limit (NDL) Warranty through Elevate — one of the most comprehensive warranties available in the commercial roofing industry, covering both materials and labor with no cap on covered repair costs.
System Specifications
- Existing System Removed
- Spray Polyurethane Foam (SPF) — Hail-Damaged
- New Insulation
- Two Layers — 2.2″ Polyiso ISO Board (Staggered)
- New Membrane
- Elevate 60 Mil TPO Single-Ply
- Code Compliance
- City of Arlington Commercial Building Code — Met
- Membrane Seaming
- Heat-Welded, Monolithic Watertight Bonds
- Primary Benefit
- Long-Term Durability, Energy Efficiency & Hail Resistance
Why Elevate 60 Mil TPO?
Not all TPO membranes are created equal. Elevate (formerly Firestone) is one of the most trusted names in commercial roofing, and their 60 mil TPO membrane represents the premium tier of single-ply roofing performance. Its enhanced thickness provides measurably better puncture resistance against future hail events, foot traffic from HVAC maintenance, and other mechanical stresses common on commercial rooftops. The bright white surface delivers exceptional solar reflectance, reducing rooftop temperatures and lowering cooling loads for the building — a meaningful benefit for a print shop whose equipment generates significant internal heat. Combined with the high-R-value polyiso insulation below, this system is engineered for both weather durability and energy efficiency.
Coverage
20-Year NDL Warranty — Elevate
No Dollar Limit · Labor & Materials Covered · Manufacturer-Backed
The CSI Difference
CSI Commercial Roofers brought the full weight of their commercial expertise to this project — coordinating material logistics, managing code compliance requirements, and executing a clean, professional installation that earned the customer a top-tier manufacturer warranty. For the print shop operators, the result is peace of mind: a roof system built to withstand North Texas weather, meet regulatory standards, and protect their business operations for the next two decades.
Whether your commercial facility has sustained storm damage or your existing roof has simply reached the end of its service life, CSI Commercial Roofers delivers proven solutions backed by industry-leading warranties.
Ready to protect your commercial property?
CSI Commercial Roofers — serving Arlington and the DFW Metroplex.