Project Spotlight: One of Evansville’s Largest Warehouse Roof Replacement After Hail Damage

Recently, our team at Embry’s Roofing had the opportunity to take on our largest project to date, replacing the roof on one of the largest buildings in Evansville, Indiana. This massive warehouse spans an impressive 350,000 square feet and is a crucial facility for its owner. The building’s existing roof was a complex layering of materials, installed over the years to meet various needs and challenges. It featured an elastomeric roof coating over a PVC membrane, laid over a layer of 1” ISO, atop a built-up roof, and finally supported by wood decking. When a severe hailstorm struck the area, the owner was understandably concerned about potential roof damage.

Identifying and Confirming Hail Damage

After the storm, the building owner asked us to inspect the roof. Upon closer examination, we discovered multiple areas where hail had impacted and damaged the structure. Hail damage is not always obvious, and often, it requires a trained eye to identify the subtle fractures and wear. We found that the PVC membrane, essential for waterproofing, had suffered fractures—even on the underside. This type of hidden damage is classic hail-related wear, but it needed validation from a structural engineer and insurance adjuster to qualify for coverage.

Collaborating with the Structural Engineer and Insurance Adjuster

When the owner filed an insurance claim, an adjuster arrived on-site to assess the extent of the damage. The adjuster recommended bringing in a structural engineer for an additional inspection, especially given the complexity of the existing roofing structure. Initially, the engineer was skeptical of hail damage being the primary cause, but after working closely with us and reviewing the damage firsthand, they recognized the unmistakable signs of hail impact on the PVC membrane. The fractures we showed them were clear evidence that the storm had indeed compromised the roof’s integrity. This led to a crucial decision by the insurance provider to cover the cost of a full roof replacement.

Selecting the Best Roofing Solution

Given the building’s extensive square footage and the need to enhance energy efficiency, we recommended a high-performance, mechanically attached TPO (Thermoplastic Polyolefin) roofing system. This approach would not only offer durability and weather resistance but would also be cost-effective for such a large installation. To further reinforce insulation, we installed two layers of 1.5” ISO and a 0.5” cover board. This upgrade met current building codes and achieved an R-value of R-20, which significantly enhances heating and cooling efficiency, reducing energy expenses and supporting the building’s sustainability.

Benefits of the New TPO Roof

The TPO roofing system we selected is known for its durability, energy efficiency, and cost-effectiveness. For a building of this size, these benefits translate to substantial savings in operational costs over time. The new roof system not only meets but exceeds energy requirements, allowing the owner to enjoy the advantages of lower heating and cooling expenses year-round. This type of roof is also resistant to UV rays and offers excellent protection against the elements—a crucial factor for a building in a region prone to severe weather.

We partnered with Mulehide, a trusted provider of roofing materials, to offer the building owner a 15-year warranty on the new roof. This warranty provides peace of mind, ensuring the building will be protected for years to come and reinforcing the value of the investment.

Value Beyond the Replacement Cost

For a project of this scale, the costs would typically be in the multi-million-dollar range. However, thanks to the insurance coverage secured due to our detailed assessment and documentation of the hail damage, the building owner only had to cover the deductible. This outcome not only saved the owner a substantial amount of money but also added significant value to the property, bolstering its structural resilience and energy efficiency. The owner was thrilled with the results, knowing the investment would deliver cost savings and enhanced property value.

A Successful Collaboration and a Thrilled Client

This project exemplifies the value of expertise, collaboration, and commitment to delivering top-notch roofing solutions. By working closely with the structural engineer, adjuster, and our dedicated team, we ensured the roof replacement was successful and met all current standards. The owner now has a secure, efficient, and robust roofing system with a long-term warranty, and the building stands ready to weather any future storms.

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