You’re about to start a reroofing project for your commercial building, and that’s exciting! Whether you’re being proactive and getting it done before serious problems arise, or you’ve been dragging your heels and are now in a time crunch, Stybek is here to relieve as much stress and confusion as possible.  

Commercial reroofing projects can be lengthy and complicated. We’d like to shed some light on this long and potentially overwhelming process with a breakdown of the steps involved. When working with Stybek, you can expect these steps: 

• Full Inspection
• Test Cut & Roof Assessment
• Pre-Start Meeting
• Cost and Timeline, Setting Customer Expectations
• Safety Precautions
• Logistics
• System Installation
• Job Closeout and Warranty 

Full Inspection 

We kick off every commercial reroofing project with a thorough inspection to uncover potential issues that could impact the final installation. Our inspection consists of several tasks in itself. 

• Interior Review 
  Our team starts inside the building by checking for signs of leaks, like water stains, rusted components, or damaged fasteners. When we locate a leak, we track it to its source to better understand which areas of the rooftop might be in trouble.
• Exterior Assessment
  After inspecting the interior, we assess the building exterior for structural compromise or water entry, which could indicate underlying issues with drainage or roof stability. We look for cracks around windows and doors, wall panels that are askew, and water stains along the masonry. We make note of existing damage if it’s present, and include that in any reporting.
• Rooftop Inspection
  Once on the roof, we look for standing water, surface damage, and debris. If you have a single-ply membrane system like EPDM, we’ll examine it for wear. We take a close look at the perimeter, gutters, flashings, and other vulnerable areas, as they are common sources of leaks and deterioration. 

Why this step is so important 

The Stybek team needs to check for any existing damage before the project begins and document pre-existing conditions to help prevent future misunderstandings or blame. It helps us immediately identify all necessary repairs, reliably and accurately informing all proceeding steps in the process. 

Test Cut and Roof Assessment 

Before or during the assessment or quoting process, we perform a test cut of the existing flat roof system to see what might be under the surface. We need to see how many layers and which materials are present, and assess the condition of these layers and the underlying insulation. To get this amount of feedback, a surface-level inspection just won’t cut it, no pun intended. 

Test cuts are especially valuable for older buildings that are more likely to have a history of multiple roof levels or overlays, where damage is likely to hide. We can uncover where improper installations happened or shortcuts were taken.  

Stybek technicians fully seal and document each test cut with a permanent patch, helping to avoid future warranty or repair concerns. By identifying trapped moisture, degraded insulation, or structural deck issues upfront, test cuts allow for more precise planning and cost estimation, making for a smoother, more suprise-free installation. 

• Flat Roof Surveys and Non-Invasive Alternatives 
  While test cuts are reliable and detailed, they are invasive, as they call for breaking the seal of the watertight membrane. In some cases, we can use non-invasive technologies like thermographic imaging or roof moisture scanners to assess insulation moisture or trapped heat patterns. As valuable as these tools are, they come with limitations: they require trained personnel and ideal weather conditions, and only work effectively on certain roofing systems at specific times of year. 
   
  While Stybek has advanced scanning equipment at our disposal, we recommend untrusting thermographic assessments to third-party consultants with the necessary technical and training qualifications. In the end, the physical test cut is the most reliable method for evaluating existing roof conditions.
• Existing Roof Assessment 
  Following the test cut, we assess the broader roof system to determine the full extent of work. This includes confirming whether one or multiple layers need to be removed, or if the roof needs to be taken down to the structural deck entirely. 

Pre-Start Meeting 

Before work begins, Stybek conducts a pre-start meeting to align everyone on what to expect throughout the reroofing process. This helps to ensure the project runs smoothly for both the building owner and our team. 

During the meeting, we walk through the planned schedule, site logistics, and safety protocols. We outline potential disruptions to daily operations. Our process helps clients understand what kinds of inconveniences might occur during the project, including: 

• Noise from tools and equipment
• Falling dust or debris from the roof deck and the option to utilize underside deck protection
• Strong odours from adhesives or sealants
• Increased foot traffic around the worksite 

This early communication helps build trust and reduces the likelihood of misunderstandings later. It’s part of Stybek’s broader commitment to transparency: setting realistic expectations while aiming to exceed them throughout the project. 

Cost, Timeline, and Customer Expectations 

Replacing a commercial roof is a significant investment, and understanding the key cost drivers and scheduling considerations can help ensure a smoother planning process. 

Factors Impacting Cost 

• Roofing Materials
  Material choice is a major cost factor. For example, metal roofing typically costs more upfront than built-up systems but may offer greater longevity. The type of system selected, whether it’s TPO, PVC, or another flat roof solution, will significantly impact the overall cost.
• Building Location
  Labour rates, regional climate, and local building code requirements can all affect pricing. In some cases, systems may require specific fasteners or coatings to meet local standards. 
• Roof Access 
  Accessibility matters! A one-storey building with open access is simpler (and less costly) to service than a high-rise or fully occupied space with limited access and staging areas.
• Labour Requirements
  The size and complexity of the roof system has a major effect on the makeup of our team. The type of roof system that the client chooses or those involving elements like built-up cold applied bitumen systems may call for additional crew members.
• Warranties
  Roofing systems may come with different warranties that in turn influence system selection and installation costs. If your project calls for a specific warranty, that will affect both the materials and the installation process.
• Tear-Off vs. Recovery
  On occasion we’re able to install a membrane system overtop the existing roof, saving time and money. We only do this in accordance with Ontario’s building code, ensuring the existing roof is in adequate shape for the recovery process. This is a common shortcut taken by contractors, but unless the conditions are ideal for a recovery, we’ll proceed with a full roof removal. The long-term reliability of your flat roof and safety of your clientele, staff, and equipment are paramount. 

Typical Cost Range 

The cost of replacing a commercial flat roof can vary significantly, and isn’t simply related to square footage. Variables such as roofing materials, building height, roof access, tear-off versus recovery approach, disposal requirements, and labour rates all affect the bottom line. Even uncommon factors like regional climate, local building codes, warranty options, and building type will impact cost. 

Rather than focusing on a fixed price range, we highlight the number of variables that shape each project’s final cost. Flat roofing systems are far more complex than the average residential roof, and pricing will reflect the unique requirements of each building. 

Timeline Considerations 

The duration of a commercial reroof can vary based on several factors: 

• Building Size
  All other things being equal, larger roofs take longer to complete. 

• Material Type
  Some materials, such as metal roofing, can take less time to install than others. 

• Existing Roof Conditions
  The condition of the roofing material and the presence of special structures (like parapets) can increase timelines. 

• Weather
  Weather can play a role, especially in winter. We will break projects into phases to avoid exposing the building to water during snowstorms or adverse conditions. Snow removal also takes a significant amount of time and resources. As much as we’d love to stick to summer projects and finish jobs on a predictable schedule, we need to be flexible with our timelines to account for Ontario’s unpredictable weather conditions.  

Safety Precautions 

We will never compromise on safety for any commercial roofing project, ever. Our crews will set up fall protection like guardrails or warning/bump lines, ensure clear signage for pedestrian areas, and coordinate staging areas to avoid hazards.  

When structural repairs or HVAC work is involved, we may also institute roof access control and internal safety protections. 

Logistics 

Do you feel like commercial reroofing projects are complicated yet? We’ve been making a big deal about the minute details involved, if only to point out how much we stress clear and thorough coordination and planning. As soon as we hit the job site, we have a plan in place for every step, including the following:  

• Pre-Project Planning 
  In the weeks leading up to installation, we’re already diligently preparing for the roofing process. We’re organizing material deliveries, arranging for equipment, and determining site logistics such as bin and truck placement. 
   
  Depending on the site layout and access points, dumpsters or portable washroom facilities may be delivered to the property 1–2 days prior to installation. We make sure to plan their location in advance to avoid blocking essential access areas, such as loading bays, garage entries, or high-traffic walkways. 
• Material Delivery and Site Setup 
  Roofing materials such as insulation, membranes, or fasteners may arrive a few days before the start date or on the morning of installation. In some cases, these materials may be staged on the roof or temporarily stored on site. 
   
  The setup may also include placement of bins or dumpsters for debris removal, portable washroom facilities for the crew, and temporary fencing or signage for safety and pedestrian redirection. 
• Clearance and Access 
  To support an efficient workflow:
  • Ensure that access points, gates, and pathways are clear for the roofing crew. 
  • Remove or cover any sensitive items near the building perimeter. 
  • Point out any specific areas of concern that may exist, such as landscaping, exterior fixtures, or storage zones. 
• During Installation 
  The tear-off process is typically the messiest part of the job. Our crews will remove the existing materials and safely dispose of them into the designated bins. Throughout the installation, supervisors may perform check-ins to monitor progress and quality. 
• Post-Installation Cleanup 
  After the new roof is installed, we’ll thoroughly clean the job site, removing all debris caused by the work. After doing a final sweep of the surrounding area, We’ll then haul all away bins, materials, and equipment.  

System Installation 

Every commercial roofing system installation has unique requirements, but some principles are universal. The structural frame of the building must be sound enough to support the roofing system, especially when heavier materials like metal are involved. Drainage systems must be in place to direct water away from the building. A low-slope design helps prevent pooling on the surface. 

That said, the exact installation process can vary significantly depending on the type of roof being installed. Here’s a high-level look at how installation differs across common commercial roof types: 

• Built-Up Roofing (BUR)
  Installed in layers, BUR systems start with a felt underlayment, followed by hot asphalt or a specific asphalt mixture. The system is topped with gravel to provide durability and UV resistance. 
• Metal Roofing 
  Metal roofs are installed using a framing system anchored to the building with fasteners. Steel sheets are placed over the frame and sealed using screws or bolts, forming a durable, weather-tight surface. We recommend placing a self-adhered underlayment directly on the substrate prior to installing the metal roof system.
• Modified Bitumen Roofing
  These systems typically include a base sheet and a cap sheet. The base may be self-adhered, while the cap can be torched down, cold-adhered, or self-adhered. Material choice, like APP or SBS, affects how the system handles UV exposure and temperature.
• EPDM Roofing 
  EPDM is installed in large rolls, with seams sealed using an adhesive to form a watertight barrier. It’s one of the simpler systems to install and replace. 
• TPO Roofing 
  TPO is a single-ply system usually consisting of conventionally installed built-up layers such as a loose-laid poly vapour barrier, two layers of ISO fastened into place, and 60 mil TPO membrane.
• PVC Roofing
  PVC is another single-ply system, which also consists of a conventionally installed built-up layers such as a loose-laid poly vapour barrier, two layers of ISO fastened into place, and (in this case) 60 mil PVC membrane. 

We dive a little deeper into the commercial roofing and installation process in this blog post. Give it a read! 

Post-Project Maintenance and Warranty 

Once your new roof is installed, you’ll require proper maintenance to protect the investment and preserve the warranty.  

• Schedule biannual inspections (spring and fall), and after major storms.
• Keep drains clear of debris, especially in fall when leaves can clog outlets.
• Promptly repair any punctures, seam lifts, or membrane issues.
• Document all work and inspections in a roof log to maintain warranty coverage.
• Consider a professional maintenance plan for long-term support.

Commercial reroofing is a lengthy, complicated process. It takes thorough, careful planning and the right team to make sure the project is completed correctly and efficiently, with minimal disruption and risk to your operation. Stybek approaches every reroofing project with transparency and attention to detail, with a commitment to safety and providing long-term value. Still have questions? We’re here to provide guidance and set you up with a no-obligation roof assessment and quote. Reach out to the Stybek team today!