Professional Built Up Flat Roof Systems Installation & Repair

After three decades of roofing in Queens, I've installed more built up flat roof systems than I can count. Just last week we completed a massive BUR installation on a commercial building in Long Island City, and it reminded me why these systems remain the gold standard for flat roofing in our climate.

Understanding Built Up Flat Roof Construction

Look, when people ask me about flat roof build up, I always start with the basics. A built up roof isn't just tar and gravel thrown on top of your building. It's a sophisticated system of alternating layers of bitumen and reinforcing fabrics that create what we call a membrane. The beauty of BUR systems lies in their redundancy - if one layer fails, you've got backup protection.

The typical built up flat roof details include a base sheet, multiple plies of felt or fiberglass reinforcement, hot asphalt or cold-applied adhesives, and a protective surface layer. We usually install three to five plies depending on the application and building requirements.

How to Replace a Built Up Flat Roof

When it comes to how to replace a built up flat roof, I'll be straight with you - this isn't a DIY project. The process involves complete tear-off of the existing system down to the deck, inspection and repair of the substrate, and installation of entirely new layers. Here's what we do at Flat Masters NY:

• Complete removal of existing roofing materials
• Deck inspection and repair of any damaged areas
• Installation of proper insulation and vapor barriers
• Application of base sheet using mechanical fasteners
• Installation of successive plies with hot bitumen
• Final surfacing with gravel, granules, or cap sheet

The whole process typically takes 3-5 days for an average commercial building, depending on weather and roof complexity.

Types of Built Up Flat Roof Systems

Not all built up flat roof systems are created equal. We work with several variations depending on your building's needs and budget:

Conventional BUR: Hot asphalt application with organic or fiberglass felts. This is what most people picture when they think of built-up roofs. We heat the asphalt to around 400°F and mop it between layers.

Cold-Applied Systems: These use solvent-based or emulsion adhesives instead of hot asphalt. They're great for buildings where hot work is restricted or when working in occupied spaces.

Modified Bitumen Hybrids: Sometimes we'll incorporate modified bitumen cap sheets over traditional BUR for enhanced weather resistance and easier repairs.

The Science Behind Flat Roof Buildup

The genius of flat roof buildup technology is in the layering. Each ply adds strength and waterproofing capability, but it's the interply mopping that creates the real seal. When we install these systems, we're essentially creating one continuous waterproof membrane from multiple components.

Temperature control is critical during installation. I've seen too many contractors rush the job and not maintain proper asphalt temperatures. At Flat Masters NY, we use thermal couples to monitor our kettle temperatures constantly. Too hot and you'll damage the felts; too cool and you won't get proper adhesion.

The surface layer serves multiple purposes beyond just protection from UV rays. Gravel provides ballast against wind uplift, reflects heat, and protects the membrane from physical damage. We typically use 400 pounds of gravel per square - that's roughly 4 tons for a 2,000 square foot roof.

Local Considerations for Queens Installations

Working in Queens presents unique challenges for built up flat roof installations. The salt air from the East River and Jamaica Bay accelerates corrosion of metal components, so we always spec stainless steel or heavily galvanized fasteners. The temperature swings we get here - from sub-zero winters to 90+ summers - put serious stress on roofing systems.

Building codes in Queens require specific wind uplift ratings, especially for buildings over three stories. We've had projects in Astoria where wind uplift calculations required additional mechanical fastening beyond the standard BUR specification.

Maintenance and Longevity

A properly installed flat built up roof should give you 20-25 years of service life, sometimes more with good maintenance. The key is addressing small issues before they become major problems. We recommend annual inspections, especially after severe weather.

Common maintenance items include repairing blisters, replacing loose gravel, and maintaining proper drainage. Speaking of drainage - and this is something I tell every customer - ponding water is the enemy of any flat roof system. If water sits on your roof for more than 48 hours after rain, you need to address it.

Cost Considerations

BUR systems typically cost less upfront than single-ply membranes, but the installation is more labor-intensive. Material costs for a quality built-up roof run about $2.50-4.00 per square foot, with labor adding another $3.00-5.00 depending on complexity and access.

The real value proposition comes from longevity and repairability. Unlike single-ply systems where a puncture might require large patch or even section replacement, BUR systems can often be repaired with simple cement and fabric patches.

Why Choose Built Up Roofing?

After installing every type of flat roofing system available, I still recommend BUR for many applications. The redundancy of multiple plies means better long-term performance. The materials are time-tested - we're essentially using technology that's been refined over 100 years.

For commercial applications with heavy foot traffic or mechanical equipment, nothing beats the durability of a well-built BUR system with aggregate surfacing. I've seen 30-year-old built-up roofs still performing while 10-year-old single-ply systems needed replacement.

Professional Installation Makes the Difference

Here's the thing about built up flat roof systems - the quality of installation matters more than with almost any other roofing type. The success depends on proper interply mopping, correct asphalt temperatures, appropriate ply staggering, and dozens of other details that only come with experience.

At Flat Masters NY, we've been perfecting BUR installation techniques for over 30 years. Our crews know how to read weather conditions, adjust for temperature changes throughout the day, and identify potential problems before they affect the finished roof.

If you're considering a built-up roof system for your Queens property, give us a call at (718) 555-0123. We'll assess your building's specific needs and provide a detailed proposal based on our extensive local experience. Every roof is different, and cookie-cutter solutions don't work in our business.

Remember, a flat roof replacement is a significant investment that affects your building for decades. Choose contractors who understand the science behind the systems and have the track record to back up their work.