Commercial Roof Replacement & Rectification

Sky Dog Roofing - Projects - Commercial - Commercial Roof Replacement & Rectification

Commercial Roof Replacement & Rectification

This project involved a large commercial property experiencing severe roof leaks despite multiple repair attempts over the years. The building’s top roof section contained large, unused industrial air conditioning ducts that had rusted through and were no longer watertight. These penetrations had been patched and resealed many times, but the system was beyond repair.

The project required full removal of the ducting, replacement of the top roof section, and targeted repairs to the lower roof. Additional challenges included difficult access to the site, crane lifting of heavy ducting and materials in a busy business district, and the presence of surrounding power lines.

Challenges

Persistent leaks despite repeated patchwork repairs.
Rusting, unused industrial AC ducting that compromised the roof structure.
Deteriorating seals and flashings across both roof sections.
Restricted access in a busy commercial area with power lines, requiring crane lifts.
Need to complete works safely without disrupting nearby businesses.

Scope of Work:

Top Roof Section

Safe removal and disposal of large industrial AC ducting from the roof.
Removal of all old roof sheets, flashings, and deteriorated material.
Crane lifting operations to remove ducting and install new roofing components.
Installation of 60mm Anticon roof insulation blankets.
Installation of new Colorbond Kliplok roof sheets (0.48 BMT).
Installation of new flashings, cappings, backtrays, and Dektites (0.55 BMT).
Installation of 150 half-round Colorbond gutters with overflow slots.
Installation of 90mm round PVC downpipes, offset and bracket-fixed to walls.

Lower Roof Section

Replacement of rusted roof screws with new Colorbond Vortex Hex Screws.
Installation of custom Colorbond backtrays (0.55 BMT).
Re-sealing and replacing rubber Dektites where required.
Sealing of flashing joins, replacement and addition of rivets where needed.
Sealing of small holes and gaps to extend roof life.
Installation of foam presstites under cappings to prevent backflow of water.
Sealing of cracks and holes around window trims to address minor leaks (noting that future glass repairs may be required).

Outcome

This project successfully transformed a failing commercial roof into a watertight, durable, and compliant system. The removal of the large rusted AC ducting eliminated a major source of leaks, while the full replacement of the top roof section provided a long-term solution. The lower roof was restored with targeted repairs and preventative maintenance, extending its lifespan without the need for full replacement.

Despite the challenges of restricted site access and heavy lifting in a busy business district, the works were completed safely and efficiently. All roofing and drainage components now function seamlessly, providing the client with a reliable system.