Commercial Flat Roof Replacement — Parsippany
Project Intro
A Parsippany commercial property owner contacted Alpha Pro Construction LLC after their existing modified bitumen system developed widespread blistering and ponding water issues. The 18-year-old system was failing at seams and around roof penetrations, causing recurring interior leaks that were affecting tenant spaces.
After a thorough assessment, we recommended a full replacement with a 60-mil TPO membrane system — offering superior heat reflectivity and weld-strength at seams over the life of the roof.
Work was carefully phased across three weekends to avoid disrupting the building’s tenants. Our commercial crew of eight handled tear-off, insulation replacement, and membrane installation in a compressed schedule that kept the building weathertight at all times.
- 60-mil TPO Membrane System
- Heat-Welded Seams & Penetrations
- New ISO Board Insulation Layer
- Tapered Insulation for Proper Drainage
Challenge & Solution
Working on an occupied commercial building presented scheduling and access challenges. The building’s HVAC units had to remain operational throughout, and deliveries had to be coordinated around tenant parking and business hours.
We solved this by creating a detailed phase plan with the property manager: roofing work was limited to 6 AM–4 PM on weekdays in designated roof zones, with HVAC units tented during work and fully functional by 4 PM each day. All material staging was done in a single designated parking area pre-approved by management.
- Phased Weekend Schedule
- HVAC Protection Protocol
- Coordinated Tenant Access
- Daily Site Clean-Up
Working Process
Core Sampling & Assessment
Multiple core cuts identified the moisture-compromised insulation zones, limiting unnecessary material removal.
Insulation & Substrate
Wet ISO board removed and replaced with new polyiso insulation, tapered at drains for positive drainage.
TPO Membrane & Details
60-mil TPO installed with heat-welded seams and custom fabricated pipe boots and curb flashings.
Delivering Results
The completed TPO roof eliminated all 14 active leak points documented before the project. The white membrane surface has measurably reduced the building’s cooling load, and the property manager reported a noticeable drop in summer utility costs for the common areas.
Alpha Pro Construction LLC delivered this project on budget and within the agreed phasing window — earning a follow-on contract for another property in the same portfolio.
