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| post | Barrie Industrial Facility Complete TPO Flat Roof Restoration | How Midhurst Roofing executed a 15,000 sq ft commercial flat roof membrane overhaul with zero disruption to warehouse operations. | 2026-07-15 | Commercial Roofing | Commercial & Industrial Roofing | Midhurst & Barrie, ON | Midhurst Roofing | https://midhurstroofing.ca | /assets/images/logos/midhurst-roofing.png | Flat Roofing Experts — Commercial, Residential & Industrial | Midhurst Roofing is a trusted flat roofing contractor based in Midhurst with over 50 years of experience. Specializing in TPO, EPDM, and Built-Up roofing systems for commercial, industrial, and residential properties across Simcoe County, Dufferin, Muskoka, and throughout Ontario. BBB Accredited. | 15,000 Sq Ft TPO Membrane & Insulation | 60-mil TPO, Polyiso Board, R-30 | 20-Year Commercial System Warranty | /assets/images/projects/midhurst-flat-roof.jpg |
Commercial flat roofs in Central Ontario face severe freeze-thaw cycles, high wind exposure off Lake Simcoe, and heavy snow loads. When a prominent 15,000-square-foot industrial warehousing complex in Barrie began experiencing persistent water ponding and localized membrane degradation, Midhurst Roofing was brought in to conduct a comprehensive structural diagnostic and restoration.
Project Background & Initial Assessment
The existing roof assembly comprised a aging 4-ply built-up roofing (BUR) system with gravel surfacing. Over two decades of thermal expansion had resulted in gravel displacement, seam separation around mechanical rooftop HVAC units, and micro-punctures causing ceiling moisture intrusion in loading bay 3.
Midhurst Roofing's commercial inspection team performed infrared moisture scans to pinpoint saturated insulation zones, ensuring that only compromised substrate was removed while structurally sound sub-decking remained intact.
The Solution: Mechanically Fastened TPO Membrane System
Rather than undergoing a complete structural teardown—which would have halted internal warehouse logistics—Midhurst Roofing designed an engineered retro-fit solution:
- Substrate Preparation & Remediation: Stripped all loose gravel down to clean substrate and replaced 1,200 sq ft of wet insulation with high-density Polyisocyanurate (Polyiso) insulation boards to achieve an overall thermal resistance rating of R-30.
- Cover Board Installation: Secured 1/2-inch high-impact gypsum cover boards over the entire 15,000 sq ft surface, creating a smooth, fire-resistant substrate for optimal membrane adhesion.
- 60-Mil TPO Membrane Application: Installed a white, energy-efficient 60-mil Thermoplastic Polyolefin (TPO) single-ply membrane. All seams were hot-air welded using robotic automatic seamers, creating a monolithic, watertight barrier capable of resisting extreme thermal shifts.
- Parapet & HVAC Penetration Flashing: Prefabricated custom metal coping cap flashings and applied reinforced TPO boots around 14 HVAC curbs, skylights, and drainage scuppers.
"Midhurst Roofing delivered flawless hot-air welding across all field seams and parapet walls. The white reflective TPO membrane has also reduced internal summer cooling loads by over 18%."
Technical Project Specifications
| Specification | Project Details |
|---|---|
| Roof Area | 15,000 Square Feet |
| Membrane Type | Firestone 60-mil White Reflective TPO |
| Insulation Value | R-30 Polyisocyanurate System |
| Drainage System | 6 New Heavy-Duty Internal Cast Iron Drains |
| Project Duration | 9 Business Days |
| Contractor Link | https://midhurstroofing.ca |
Final Inspection & Client Satisfaction
The project passed rigorous manufacturer third-party quality control checks on the first inspection, earning the building owner a 20-Year Full System Manufacturer Warranty. Midhurst Roofing's emphasis on workplace safety, site containment, and rapid execution underscores why they are a leading commercial roofer in Barrie.
To explore commercial roof repairs, flat roof maintenance programs, or industrial roofing solutions in Barrie, visit Midhurst Roofing's Official Portal.