Commercial Plaza TPO Flat Roof Replacement Fort Lauderdale
Turnkey 28,000 sq ft commercial flat roof replacement for a prominent retail shopping plaza along Federal Highway in Fort Lauderdale, replacing a leaking multi-ply asphalt roof with a robotically welded Carlisle 80-mil TPO system backed by a 20-Year NDL manufacturer warranty.
The Roofing Challenge: Saturated Deck, Active Leaks & Severe Ponding Water
The 28,000 sq ft commercial plaza housed 8 retail tenants whose businesses were threatened by chronic roof leaks during summer deluge rainstorms.
Core testing revealed that the existing multi-ply asphalt built-up roof had suffered widespread moisture saturation across 40% of its fiberglass insulation core. Severe structural deck deflections had created permanent ponding water reservoirs up to 3 inches deep around rooftop package AC units.
Because the plaza housed operating restaurants, boutique fitness centers, and medical retail, the reroof could not cause interior ceiling leaks, odorous asphalt fumes, or customer parking lot closures. Planet Construction engineered a phased, low-odor, single-ply solution.
The Engineering Execution: Phased Commercial Single-Ply Assembly
Directly managed under Master Roofing License CCC1329271, our commercial crews completed daily tear-offs and tie-ins to maintain 100% watertight security every evening.
Complete Tear-Off & Structural Deck Pull-Testing
Old gravel, asphalt plies, and waterlogged insulation were removed to the bare structural deck. TAS 105 fastener pull-tests verified 450+ lbs uplift resistance per anchor.
TAS 105 Fastener Pull-Test VerifiedSelf-Adhering Vapor Retarder & Air Barrier
Application of high-performance self-adhered vapor barrier over the primed concrete deck, preventing internal humidity migration into the insulation matrix.
ASTM D1970 Vapor Barrier • Perm < 0.1Tapered Polyiso Insulation Slope-to-Drain System
Engineered multi-layer staggered polyisocyanurate insulation boards providing an R-30 thermal barrier and a precision 1/4-inch per foot slope to scuppers and internal drains.
ASTM C1289 Class 1 • Zero Ponding GuaranteeHigh-Density HD Gypsum Cover Board Layer
Installation of high-density fiberglass-mat gypsum cover board mechanically fastened to provide severe hail protection (UL 2218) and high foot-traffic durability.
ASTM C1177 Severe Hail ClassificationRobotically Welded 80-Mil Carlisle TPO Membrane
Rolls of white reflective Carlisle 80-mil TPO membrane heat-fused using computer-controlled robotic hot-air welders at 1,000°F, probed 100% along all lap seams.
ASTM D6878 • Robotic Hot-Air Fused Monolithic SeamsTechnical Specifications & Municipal Verification Log
Every material and method deployed adhered strictly to Florida Building Code, manufacturer warranties, and signed engineering calculations.
| Scope Parameter | Engineered Specification | Governing Standard | Verification Method |
|---|---|---|---|
| Membrane Specification | Carlisle Sure-Weld 80-mil Polyester-Reinforced White TPO | ASTM D6878 Type 1 |
Carlisle Factory Inspector Sign-Off |
| Thermal Insulation & Slope | Dual-layer staggered polyiso (R-30) with 1/4-inch per foot tapered cricket system | FBC Energy Conservation Code |
Slope-to-Drain Verification on Site |
| Cover Board Protection | 1/2-inch Georgia-Pacific DensDeck Prime fiberglass-mat gypsum roof board | ASTM C1177 Hail • FM 1-90 |
Fastener Embedment Inspection |
| Seam Welding Method | Robotic hot-air seam welder calibrated to 1.5-inch fused weld width | Manufacturer Specification |
100% Seam Probe Manual Test |
| Warranty Type | 20-Year Manufacturer No Dollar Limit (NDL) Labor & Material Warranty | Carlisle Golden Seal NDL |
Official Manufacturer Certificate |
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Request Project Estimate for Your Property
Contact our engineering and estimating department to review architectural plans, schedule an on-site structural takeoff, or coordinate municipal permit filings directly with qualifying contractor John Kraja.
Central Office: (754) 301-6747
Official Office Email: office@planetconstructionservices.com
Direct Dispatch: 1500 NE 51st St, Fort Lauderdale, FL 33334
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