Are you considering a built-up roof for your property but aren’t exactly sure what it entails? You’re not alone—many business owners are curious about how this roofing option works and its benefits. Known for its durability and cost-effectiveness, a built-up roof, also called BUR, has been a reliable roofing solution for over a century. This guide will walk you through everything you need to know about built-up roofs, including:
- What a built-up roof is and its key materials
- The installation process of a built-up roof
- How to maintain a built-up roof for longevity
🤔 What Is a Built-Up Roof?
A built-up roof (BUR) is a multi-layer roofing system commonly used on flat or low-slope roofs. It gets its name from the “built-up” process, which involves alternating layers of reinforcing materials, such as fiberglass or organic felt, and bitumen (asphalt or coal tar). The topmost layer is typically finished with gravel or a reflective coating to protect the layers below from UV rays and weather damage.
Key Materials in a Built-Up Roof
- Bitumen: A waterproof adhesive that binds the layers together. Options include asphalt or coal tar.
- Reinforcement Layers: These can include fiberglass, organic felt, or other materials that provide strength and stability.
- Surfacing Layer: Often gravel or reflective coating, this protects the layers from sunlight, foot traffic, and water pooling.
✅ 5 Steps to Install a Built-Up Roof
Here’s a step-by-step guide to how professionals install a built-up roof:
1. Roof Preparation
Before any installation begins, the roof must be carefully prepared to ensure the success and longevity of the roofing system. This process starts with thoroughly cleaning the roof surface to remove all dirt, debris, and contaminants that could interfere with the adhesion of materials. A clean, smooth surface is essential for achieving proper bonding between the roof deck and the layers to come. Additionally, this step includes assessing the roof for any damage or weaknesses, such as cracks, gaps, or structural issues. Repairs are made where necessary, including filling gaps, replacing damaged sections, and reinforcing weak areas to create a strong and stable foundation. Skipping or rushing through this step could compromise the integrity of the entire roofing system, so attention to detail during preparation is critical. Proper roof preparation ensures that the materials applied later adhere securely, ultimately contributing to the long-term performance and durability of the roof.
2. Apply the Base Sheet
With the roof fully prepared and repaired, the next step is applying the base sheet, which acts as the foundation of the entire roofing system. The base sheet is a critical element, providing an initial protective layer and a uniform surface to support the subsequent layers. Depending on the type of roof and the materials being used, the base sheet may be adhered to the roof deck using strong adhesives, mechanically fastened with screws and anchors, or applied via other appropriate methods. This process ensures the sheet is securely attached to prevent movement, air pockets, or uneven surfaces. The base sheet plays a vital role by providing a foundational barrier that enhances protection against moisture and creates an even surface for installing the next layers. Without a properly installed base sheet, the roofing system could lose stability and fail to perform as intended.
3. Layering Bitumen and Reinforcement
The core strength and waterproofing capabilities of the roofing system come from alternating layers of hot bitumen and reinforcement materials. This step begins with heating the bitumen to the appropriate temperature, ensuring it reaches the correct viscosity for even application. The hot bitumen is then carefully spread across the base sheet, creating a uniform layer of adhesive material. Next, reinforcement materials such as felt or fabric are laid directly onto the bitumen while it is still hot. These materials are expertly positioned to ensure full coverage and alignment, avoiding wrinkles or gaps that could lead to weaknesses. The process is repeated, layering bitumen and reinforcement multiple times to build a durable, watertight barrier. Each layer is carefully bonded to the one below it, creating a seamless roofing system capable of withstanding extreme weather conditions, including heavy rain, snow, and strong winds. This step is crucial for ensuring the roof’s structural integrity and its ability to protect the building for many years to come.
4. Final Surfacing
The final layer of the roofing system serves a dual purpose: enhancing durability and providing additional protection. This top layer may include a variety of materials, depending on the specific requirements of the roof and its intended function. Common options include gravel, which adds weight and resistance to physical damage, or mineral-surfaced cap sheets, which provide added strength and durability. Reflective coatings are another popular choice, particularly for buildings in hot climates, as they help improve energy efficiency by reducing heat absorption and lowering cooling costs. This top layer also protects the roof from harmful UV rays, which can degrade materials over time, and adds resistance to foot traffic, making it more durable during inspections or maintenance work. By selecting the right surfacing materials, the roof is made more resilient to environmental challenges while also enhancing its overall performance and aesthetic appeal.
5. Inspection
Once all layers of the roofing system have been installed, the final but equally critical step is a thorough inspection. This step ensures that the roof meets high standards of quality, durability, and performance. Every section of the roof is carefully examined for potential issues, such as improper adhesion, uneven layering, or vulnerabilities that could compromise the roof’s integrity. Inspectors check the seams to ensure they are properly sealed and verify that all materials have been applied correctly and securely. Any irregularities or concerns identified during the inspection are promptly addressed, ensuring the roof is fully functional and reliable. A well-executed inspection provides peace of mind to the building owner, confirming that the roofing system is built to last and capable of withstanding the elements. This final step is essential for delivering a high-quality roofing system that will protect the building and its occupants for years to come.
🛠️ How to Maintain a Built-Up Roof
One of the key advantages of a built-up roof is its longevity. With proper maintenance, these roofs can last 20 to 30 years or more. Here are some tips to keep your BUR in top condition:
Regular Inspections
Inspect your roof at least twice a year to catch potential problems early. Look for cracks, blisters, loose gravel, or any visible signs of wear and tear. Early detection can prevent minor issues from becoming costly repairs down the line.
Keep It Clean
Debris like leaves, dirt, and branches can accumulate on your roof and lead to water pooling, which causes damage over time. Make it a habit to clean your roof regularly and ensure your gutters are free of blockages to allow proper drainage.
Address Issues Promptly
Don’t ignore small cracks or leaks. These minor issues can quickly spiral into serious problems, such as water damage or structural weakening. Repairing cracks or leaks as soon as you spot them can save you time and money in the long run.
Professional Maintenance
While regular self-inspections are helpful, it’s essential to have your roof professionally inspected and maintained at least once a year. A trusted roofing contractor like Maumee River Roofing has the expertise to spot hidden issues and provide the necessary repairs or upkeep to ensure your roof lasts for years to come.
🏡 Built Up Roofs
At Maumee River Roofing, we understand the importance of a reliable, durable roof for your commercial property. With our unmatched expertise in built-up roofing, commitment to quality materials, and customer-first approach, we’re the team you can trust to deliver exceptional results.
Whether you’re looking for a new installation or need expert advice, our experienced professionals are here to guide you every step of the way. Don’t leave your roofing needs to chance—contact Maumee River Roofing today for a free consultation and see why we’re the trusted choice for commercial roofing solutions!
