Gypsum Deck Challenge Conquered: $80K Saved and Project Completed in Half the Time with Innovative Roofing Solution

WHEN PRECISION MEETS PERFECTION

Cutting Costs and Stopping Leaks: How Lancaster Roofing Saved $80,000 for Client and Finished in Half the Time with Carlisle VacuSeal Technology

Challenges and Solutions: Roofing for a TPO Membrane Over a Gypsum Deck

Challenges: The project’s most significant challenge was the existing gypsum roof deck, which complicated the use of traditional mechanically fastened systems. After conducting a fastener pull test with OMG, it was determined that the gypsum deck would not meet the required pull values. A fully adhered system was an option, but it would have required gluing both the insulation board and the TPO, which would have increased the costs by $80,000.

Solution: Lancaster Roofing utilized Carlisle's niche VacuSeal Roof System, which enabled the roof installation without adhesives or fasteners. The VacuSeal Vents, spaced strategically across the roof, utilized the power of wind to create suction and secure the TPO membrane, delivering a cost-effective and fast installation.

Benefits of the Carlisle VacuSeal Commercial Roofing System in Grand Prairie, Texas

The VacuSeal™ Vent System offers numerous advantages for commercial roofing projects:

• Negative Air Pressure for Enhanced Security: The system utilizes negative air pressure to remove excess air from beneath the roof membrane, creating a vacuum effect that locks vents and roofing components securely into place. This ensures the membrane stays tight and well-secured, even in high winds.
• Reduced Costs: By eliminating the need for adhesives and fasteners, the client saved approximately $80,000 compared to a fully adhered system.
• Faster Installation: The roof was completed in just three days, half the time a traditional roofing system would require. This minimized operational disruptions for the client.
• Superior Wind Resistance: Tested up to 195 psf in high-speed wind tunnels, including at NASA, the VacuSeal system delivers extreme wind resistance. It also meets Florida building code standards for high-velocity hurricane zones.
• Eco-Friendly Installation: With no adhesives, the system avoids VOC emissions and odors, supporting sustainable practices. Additionally, it has no cold-weather limitations, allowing installations year-round.
• Energy Efficiency: The TPO membrane reflects solar heat, reducing energy consumption and keeping the building cooler, which is essential for the Texas climate.

These benefits highlight how the VacuSeal system combines innovation, performance, and cost-efficiency, making it an ideal roofing solution for commercial properties with complex structural challenges.

Project Highlights: Fast, Secure, and Cost-Effective Grand Prairie Roof Installation

Despite the challenges of working with a gypsum deck, Lancaster Roofing’s use of the VacuSeal system allowed for a quick and efficient installation of the new TPO roof. The project was completed with no disruptions, and the property now enjoys a robust roofing system that ensures leak protection and energy efficiency.

• Zero Fasteners or Adhesives: The adhesive-less installation minimized environmental impact and allowed for a swift setup, even in cooler weather.
• Long-Term Durability: VacuSeal’s resistance to high winds makes it a long-lasting solution that will stand the test of time, even in extreme weather conditions.

Client Satisfaction

The client was thrilled with the results, particularly with how quickly the project was completed. In under five working days, Lancaster Roofing transformed the old, leaky roof into a modern, secure roofing system. The property is now better protected from Texas’s unpredictable weather, and the client can rest easy knowing future rains won’t bring leaks.

Maintenance Recommendations for Long-Lasting Performance

To ensure the longevity and optimal performance of the newly installed Carlisle VacuSeal TPO roof system, we recommend the following maintenance practices:

• Annual Roof Inspections: Schedule a professional roof inspection at least once a year to identify and address any potential issues early. Regular inspections help prolong the life of the roof and maintain its warranty compliance.
• Quarterly Debris Removal: Clear any debris, such as leaves, branches, or dirt, from the roof and drainage areas every quarter. Accumulated debris can block water flow, leading to pooling and potential damage to the membrane.
• Monitor for Punctures or Tears: Although the VacuSeal system provides excellent wind resistance and durability, check periodically for punctures or membrane damage, especially after severe weather events.
• Ensure Vent Performance: Verify that the VacuSeal vents remain unobstructed and in proper working condition. These vents play a crucial role in keeping the membrane secure and should be kept clear of blockages.
• Gutter and Drain Cleaning: Regularly clean gutters, downspouts, and internal drains to prevent water backup, which could lead to water infiltration.

By following these maintenance steps, the client can enjoy the full benefits of the Carlisle VacuSeal system and ensure it remains a reliable, leak-proof solution for years to come.

Conclusion

The roof replacement at 1202 N Great Southwest Parkway in Grand Prairie, Texas, demonstrates Lancaster Roofing’s commitment to providing innovative and cost-effective solutions. By leveraging the Carlisle VacuSeal TPO Roof System, we overcame the challenges posed by a gypsum deck and avoided the high expenses of a fully adhered system. This niche solution not only saved the client approximately $80,000 but also ensured a fast, three-day installation, completed in half the expected time.

The VacuSeal system's adhesive-free design, extreme wind resistance, and environmental benefits provide long-term value and durability. With the client thrilled by the seamless installation and confident in their new leak-proof roof, this project highlights Lancaster Roofing’s expertise in tackling complex challenges while delivering superior results.

Our approach ensures the client now has a high-performance roof ready to withstand the demands of Texas weather. With recommended maintenance practices in place, the roof will offer long-lasting protection and peace of mind for years to come.

For a free inspection or to learn more about Lancaster Roofing’s commercial roofing services; roof repair, roof replacement, on all industrial roof types , call (214) 247-6388 today.