Location: Steubenville, OH
Facility Type: Small Commercial Building
Project Type: Double-Layer Tear-Off & Full Roof Replacement
Size: 17,600sqft
Warranty: 20-Year NDL Material & Labor Warranty
Project Overview
Known on our team as the Triangle Building, this project presented a series of unique structural and logistical challenges. With a double-layer tear-off involving a single-ply membrane over an older gravel-surfaced built-up roof, the scope required precise planning, close coordination with the building owner, and careful timing to work around live operations inside the facility.
Because the building remained operational during the entire construction period, communication and flexibility were key. We also faced the added complexity of angled decking, which required customized removal and replacement techniques—all while the building was fully open to the sky.
Scope of Work
Roof Tear-Off & Substrate Replacement
- Removed two layers of roofing: top layer single-ply membrane and bottom layer built-up gravel roof
- Replaced sections of damaged or deteriorated angled decking, requiring precision installation
- Coordinated closely with building occupants to ensure indoor areas remained safe and unaffected Insulation & Membrane Installation
- Installed two layers of 2.2” ISO insulation to meet R-value requirements
- Placed a 6-mil vapor barrier between insulation layers to prevent condensation
- Installed a 50 mil Duro-Last single-ply membrane, fully adhered for long-term protection
Flashing & Finishing
- All standard Duro-Last flashings and details installed around curbs and penetrations
- Delivered with a 20-Year NDL (No Dollar Limit) Warranty covering both material and labor
Challenges & Solutions
Challenge
- Double-layer roof system with built-up gravel
- Angled decking in a uniquely shaped structure
- Fully occupied building during construction
- Opened roof exposed interior to weather
Solution
- Careful tear-off and debris removal to expose and assess decking beneath
- Customized decking repair approach with angled cuts and specialized materials
- Tight coordination with owner to maintain operations and minimize disruption
- Scheduled tear-off in tight windows with clear forecasts; avoided exposure to rain
Results & Value
The Triangle Building now benefits from a clean, code-compliant roofing system that’s ready to perform for decades. With improved thermal insulation, moisture protection, and a watertight Duro-Last membrane, the building owner can now focus on operations—without worrying about future leaks or deck deterioration.
This project was a testament to our ability to handle complex tear-offs, unique building shapes, and active environments—all while delivering on time, on budget, and to the highest quality standard.