Identifying Commercial Roofing Issues Early Prevents Costly Repairs
An industrial facility’s roof isn’t something most facility managers think about on a day-to-day basis. No matter what commercial building roof type you have, it’s out of sight and out of mind until there is a roofing emergency.
According to Risk & Insurance magazine in 2024, a “survey of business owners found that 91% of respondents are concerned about the effect of severe weather on their businesses.” That Gallagher survey also revealed a growing worry among business owners that their insurance coverage may not be sufficient to pay for future losses; a critical issue as the nation faces ever-worsening weather extremes.
To avoid costly problems and lost productivity due to weather-related issues or any type of roof damage, facility managers need to address small commercial roof problems, including normal wear and tear as well as damage from severe storms, before they become larger ones.
In this article, we will discuss early signs of commercial roofing issues you should be on the lookout for, other concerns that could lead to roof problems, and how to be proactive and prevent costly roofing emergency repairs.
Early Signs of Commercial Roof Issues
Loose or Missing Roofing Material
Some signs your roof isn’t functioning properly are finding shingles or loose granules from the shingle’s surface on the ground around your facility. Whether it’s shingles, panels, or membrane sheets, the discovery of any missing roofing material indicates there is a problem, and leaves the roof vulnerable.
A roof that has long-term exposure to extreme weather or that encounters damaging air pollutants or chemicals will also have problems, because of the negative effects these elements have on the roofing materials.
Blistering or Bubbling
Blistering or bubbling can happen when air or moisture gets trapped between roof layers. This phenomenon often occurs in membrane roofs like TPO or EPDM. Over time, this moisture weakens the structure. To ensure blistering and bubbling does not occur, you should inspect the following every six (6) months:
- Interior Roof Deck
- Field of Roof
- Ceiling
Cracks, Tears, or Punctures
Any visible damage to roofing material, such as a crack, tear, or puncture, can let water in and cause leaks. These issues can be especially prevalent around vents, seams, or flashing. Similarly, cracks in your facility’s interior ceilings and walls could also indicate a problem.
A common misconception is that cracks are a normal sign of wear and tear or could be the result of a building settling. However, cracks and misshapen support structures are almost always a warning sign that something unnatural is occurring with your commercial structure and indicate immediate attention is necessary.
To ensure cracks don’t occur, you should inspect the following every six (6) months:
- Exterior Walls
- Field of Roof
- Penetrations
- Ceiling
Damaged Flashing or Membrane
Flashing protects the roof’s edges, walls, and equipment. If it’s bent, corroded, or missing, water can sneak through the gaps and cause leaks. A roof’s membrane, on the other hand, provides a durable, waterproof, and weather-resistant covering for the roof. If your commercial roof’s flashing or membrane is damaged, it’s going to cost money to get them repaired.
To ensure your roof’s membrane and flashing don’t become compromised, you should inspect the following every six (6) months:
- Field of Roof
- Penetrations
- Base Curb Flashing
- Roof Edges
- HVAC Units
Interior Water Stains or Leaks
If you see water stains on the ceiling or walls inside your facility, the roof may already be compromised and could indicate a commercial roof leak. Keep in mind that improperly added equipment or anything else on the rooftop, including human foot traffic, can also result in water leaks.
To proactively check for signs of leaks, you should inspect the following items every six (6) months.
- Interior Roof Deck
- Ceiling
- Interior Walls
- Exterior Walls
- Expansion Joints
- Fascia/Coping/Metalwork
Here’s a useful article on water leaks: “Inspect Your Commercial Roof from the Inside to Spot a Problem on the Outside.”
Mold, Mildew, or Musty Odors
Biological growth, including vegetation in areas on the rooftop or standing water, can be signs there is trapped moisture, which weakens a roof’s structure and impacts indoor air quality. Changes in the use of a building, especially adjustments that increase or decrease the interior’s relative humidity, can also cause severe condensation problems within the roofing system, resulting in mold, mildew, or musty odors.
Sagging Roof
A healthy roof should look flat and even. Sagging could point to underlying damage or structural issues. Sagging is also an indication a commercial roof is experiencing a significant amount of weight or pressure in a low spot. Low points on a roof can also gather water and will continue to do so until the issue is addressed. If water cannot drain properly, especially after a significant snowfall or rainstorm, sagging is known to become a potential problem. As such, pay special attention to this potential issue after a storm.
If a roof is compromised and pressure is being applied to different components, it can move fire sprinkler heads out of their normal positions. If you notice parts of the sprinkler system, such as the piping or the sprinkler heads themselves appear to be warped, it could mean there is a larger issue. The weight of a sagging roof can also cause a sprinkler system to bend. If this happens, in addition to fixing the roofing, you’ll also need to have the sprinkler system repaired.
Another problem a sagging roof can create is warped interior door frames. If you notice your door frames look misshapen or your employees have a difficult time opening or closing a door they had no issues with previously, it could also be a sign your commercial roof is sagging.
Debris or Clogged Drains
If you see water pooling on the roof after it rains and it doesn’t drain within 48 hours, it’s a red flag that there are drainage issues or sagging areas. Blocked drainage can cause water to back up, speeding up deterioration. Although there are many different commercial building roof types—single-ply, spray foam, metal, and shingle—for proper drainage to be achieved, a flat or sloped roof must have the proper drainage system installed by a professional commercial roofing contractor.
You can ensure your roof drains properly by inspecting the drainage system every six (6) months. Proper roof drainage will:
- Prevent Water Damage
- Extend a Roof’s Lifespan
- Reduce Roof Weight Load
- Prevent Ice Dam Formation
- Minimize Moisture-Related Issues
- Support the Energy Efficiency of Your Facility
Check out our blog on proper roof drainage.
Increased Energy Bills
Commercial roofs often have insulation layers beneath the roof membrane. Frequent walking on a rooftop can compress the insulation, reduce its effectiveness, and lead to higher energy bills due to poor thermal performance. Wet insulation or failing roofing materials can also lead to spiking energy costs. If either of these occur, your HVAC system may have to work harder to maintain indoor temperatures.
Liquid Roofing
Liquid roofing refers to a specialized coating—typically made of polyurethane, acrylic, silicone, or other elastomeric materials—that is applied directly to a roof’s surface in liquid form. It then cures to create a seamless, waterproof membrane that protects the roof. However, if the liquid roofing is not working properly, it could result in many of the issues previously mentioned. These include:
- Ponding water that won’t drain
- Cracking and splitting
- Blistering and bubbles
- Peeling and delamination
- Discoloration or fading
- Soft or spongy spots
- Visible rust or corrosion
- Mold, mildew, or musty smells
Other Issues Contributing to Commercial Roofing Problems
While the following items don’t present as a visible sign your commercial roof has difficulty, these issues can cause roofing problems:
- Bad installation
- Roof’s age/old roof
- Lack of maintenance
- Foot traffic
Foot Traffic
Many facility owners don’t think about the impact foot traffic has on a flat roof, which can take a surprising toll on the rooftop to include:
- Membrane damage: Due to punctures, tears, scraping, and scuffing
- Compressed insulation: Reduction of insulation’s effectiveness leads to higher energy bills
- Drainage issues: Foot traffic can unintentionally shift or dent a roof’s structure, which results in drainage problems
- Accelerated wear and tear: High foot traffic can cause premature roof aging, which results in the need for early repairs, or a potential replacement
Here are some things that facility managers can do to prevent foot traffic issues:
- Install walk pads
- Limit roof access
- Educate maintenance crews on proper walking paths and vulnerable areas to avoid
How to Prevent Costly Roofing Repairs
If you are noticing some signs of potential roof damage at your commercial facility, contact a reputable roofing company like Capital Roof Care (CRC) to help. CRC specializes in conducting industrial roof inspections and commercial roof assessments for all types of commercial roofs and can create a specialized roof care service plan for your facility.
In the northeast, we experience snowstorms during the winter and thunderstorms, which can include hail, in the summer. The effects of severe storms that can impact an industrial roof include wind uplift damage, structural damage, and reduced energy efficiency. As part of your CRC roof care service plan, a CRC team member can come to your facility following a severe storm to ensure there are no resulting roofing issues.
More specifically, after a hailstorm, it’s imperative to check your roof for dents, cracks, tears, punctures, and displaced aggregate. With a CRC roofing professional by your side, we can document all storm damage with photographs and detailed notes, in addition to suggesting and making any necessary roof repairs.
For more information about CRC and to set up the roof care service plan that’s right for your company, contact us today. By doing this and being proactive, you can prevent costly roofing emergency repairs.
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