Case Studies

PROJECT: NATIONAL HOME IMPROVEMENT RETAILER

OBJECTIVE: PRE-SOLAR ARRAY INSTALLATION INSPECTION & PHOTOVOLTAIC (PV) PANEL INTEGRATION

PROJECT SIZE: APPROXIMATELY 98,00 SQUARE FEET

ROOF COMPOSITION: EPDM MEMBRANE

THE SITUATION:

A national retailer leveraged its extensive rooftop footprint to install solar systems as part of its renewable energy strategy. Since launching a pilot program, the initiative has expanded to more than 80 locations, reducing grid dependence by an estimated 30–35% annually and lowering operating costs. This approach reflects a growing trend among commercial property owners to convert unused roof space into revenue-generating, energy-efficient assets.

Solar PV systems convert sunlight into electricity using semiconductor panels, typically with a lifespan of 25–30 years. The system produces direct current (DC), which is converted into usable alternating current (AC) for building operations. Modern high-efficiency panels can help commercial properties lower energy costs and improve long-term ROI.

THE SOLUTION:

Our disciplined, detail-driven approach protects the client’s roofing asset, enables seamless solar integration, and preserves warranty coverage, minimizing risk and safeguarding long-term property value.

1. WARRANTYCheck® Assessment

We enacted a protective warranty integration plan to ensure the PV system is installed without compromising roof performance or the manufacturer’s warranty. We coordinated the formal modification of the existing warranty to recognize the solar installation and managed all required registrations and documentation for overburden (additional roof weight) waivers.

2. THREATCheck® Assessment

A manufacturer-coordinated pre-solar inspection confirmed the roof was defect-free and suitable for installation. Following construction, a post-solar inspection verified the system remained watertight and compliant. Any identified items were documented and resolved to maintain full warranty protection.

3. Solar Support

To support the solar array, we installed nineteen (19) manufacturer-approved mechanical attachment points designed to provide a secure, watertight connection to the EPDM roofing system. Each attachment was engineered for the roof assembly and deck type to ensure structural integrity and long-term performance

THE RESULTS

The Pre-Commercial Roof Solar Preparedness Inspection and specialized anchor installation ensured the roof was structurally sound, watertight, code-compliant, and fully prepared to support a solar PV system throughout its entire lifespan,

THE TAKEAWAY:

Proactive planning and customized solutions are essential to protecting both the roof and the solar investment. A commercial roof is a complex building system with structural limits, drainage design, and warranty requirements, not merely a platform for solar panels. By verifying load capacity, confirming remaining roof service life, and using manufacturer-approved attachment methods, we protected warranty coverage and waterproofing integrity.

THE LESSON:

By combining advanced technology with expert analysis, our distinctive, precise approach ensured moisture-affected areas were accurately identified and defined, enabling targeted repairs and cost-effective planning.

As difficult as it may be to believe, incidents like this are standard. When a newer roof system is installed over an older one still underneath, moisture can become trapped between the two layers. In such cases, water usually does not enter the building, or only does so minimally, leaving occupants unaware of the problem’s severity.

Taking measures, such as seasonal preventative maintenance, helps detect potential issues early and enables proactive upkeep rather than reactive repairs.

SOLAR READY SUPPORT FROM YOUR CHIEF ROOFING OFFICERS:

Our expert Roof Advisors ensure your roof is solar-ready with comprehensive WARRANTYCheck® & THREATCheck® Assessments conducted before installation. We provide pre-installation evaluations, recommend necessary repairs, perform post-installation inspections, and deliver rapid service to prevent leaks, avoid costly panel removal, and maximize return.

YOUR CHIEF ROOFING OFFICERS:

At PB Roofing, we serve as your Chief Roofing Officers, delivering comprehensive commercial roofing solutions through our dedicated Client Experience team. From routine maintenance to large-scale projects, we handle it all under one roof.

Our in-house crews respond to emergencies within 24 hours, and our proactive asset management extends roof life, controls budgets, and prevents disruptions. With a safety-first culture and consistent East Coast coverage, we deliver reliable, on-time performance you can count on.

TOP 3 RELEVANT KNOWLEDGE HUB BLOG BACK ISSUES:

Top 5 Financial & Environmental Benefits of Commercial Solar Installation

How Does the Federal Solar Tax Credit Work?

Benefits of Solar Panels for Commercial Buildings

PROJECT: AMREX CHEMICAL COMPANY, INC.

OBJECTIVE: THERMAL IMAGE DETECTION OF MOISTURE-AFFECTED ROOF INSULATION & REPLACEMENT

PROJECT SIZE: APPROXIMATELY 37,800 SQUARE FEET

ROOF COMPOSITION: PVC MEMBRANE WITH 2” INSULATION AND METAL DECKING

Amrex Chemical Co., Inc. is a wholesale chemical distributor based in Binghamton, NY. Founded in 1982 by William F. Rexer, Jr., the company began at its headquarters on East Frederick Street. Over the past 30 years, it has expanded throughout the Southern Tier of New York with several warehousing locations.

BEFORE THE PROJECT:

After recurring roof leaks disrupted daily operations and raised concerns about interior damage, Amrex contacted our team to identify the source of the problem. To prevent further damage and costly shutdowns, we immediately moved forward with a scope of work to quickly and accurately diagnose the issue.

OUR STRATEGIC APPROACH:

Our team conducted a detailed infrared moisture survey to identify areas where insulation may have been damaged by water intrusion. This technique is completely non-destructive and uses advanced thermal imaging to spot anomalies in the roof system. By detecting heat signatures trapped within wet insulation or between membrane layers, we can identify problem areas without cutting into the roof or interrupting the building’s operations.

To perform the analysis, PB Roofing used the Fluke Ti480P Thermal Imaging System, one of the industry’s leading diagnostic tools. This camera detects electromagnetic thermal energy emitted from roof surfaces.

We found 44 moisture-related thermal patterns covering 8,562 square feet of roofing.

This is approximately 23% of the total roof surface.

OUR SPECIALIZED SOLUTION

After clearing out the wet areas, we installed new insulation and a new TPO roofing membrane to seal and protect the roof. All edges, walls, and roof fixtures were properly sealed to prevent future leaks, and new drainage components were added where needed. Walkway pads were placed in high-traffic service areas to protect the roof surface. Once the work was complete, all debris was removed, leaving the building with a clean, watertight, and long-term roofing solution.

• Repair of damaged metal decking (to avoid rusting)
• Replacement of damaged roof drains
• Replacement of damaged wood nailer (to avoid rot)
• Replacement of damaged insulation
• Main roof area replaced with TPO membrane

THE OUTCOME:

Due to the customized, strategic approach tailored to Amrex’s operational needs, the moisture intrusion issue was entirely resolved, and the roof was restored to a watertight, high-performing condition.

By targeting specific problem areas with tailored remediation rather than a generic solution, we eliminated the leak source, replaced damaged materials, and strengthened the roof system to prevent future issues. With the moisture concerns resolved, Amrex can now confidently focus on its core operations, trusting its roof’s reliability.

THE LESSON:

By combining advanced technology with expert analysis, our distinctive, precise approach ensured moisture-affected areas were accurately identified and defined, enabling targeted repairs and cost-effective planning.

As difficult as it may be to believe, incidents like this are standard. When a newer roof system is installed over an older one still underneath, moisture can become trapped between the two layers. In such cases, water usually does not enter the building, or only does so minimally, leaving occupants unaware of the problem’s severity.

Taking measures, such as seasonal preventative maintenance, helps detect potential issues early and enables proactive upkeep rather than reactive repairs.

THREATCHECK PLUS PREVENTATIVE MAINTENANCE:

PB Roofing’s THREATCheck Plus preventative maintenance program begins with a thorough assessment of the roof’s overall condition. This initial report identifies both emergency and non-emergency issues and provides a projected budget for roof replacement if necessary. From there, we create a customized plan based on the roof’s condition. Additionally, we ensure compliance with the manufacturer’s warranty requirements, which typically require annual maintenance.

YOUR CHIEF ROOFING OFFICERS:

At PB Roofing, we serve as your Chief Roofing Officers, delivering comprehensive solutions through the nation’s only dedicated commercial roofing Client Experience team. Whether it’s routine maintenance or large-scale projects, everything you need is handled under one roof.

When emergencies occur, our in-house crews are ready to respond on-site within 24 hours. We also provide proactive asset management to help you plan budgets, extend roof life, and prevent operational disruptions.

Every project is completed with a focus on deadlines, ensuring punctuality as standard, not just a goal. Our safety-first culture prioritizes protecting your people, property, and business operations. With extensive coverage across the East Coast, we deliver consistent, high-quality service wherever you need us.

TOP 3 RELEVANT KNOWLEDGE HUB BLOG BACK ISSUES:

10 Steps to Choosing the Right Commercial Roofing Contractor (November 2024)

Your Quick Guide to Fall Commercial Roof Inspection (August 2024)

Protecting Commercial Roofing from Mold & Algae (January 2024)

Project: Trinity Lutheran Church, Tenalfy, NJ

Objective: Roof Section and Skylight Replacement, Adjacent Wall Repair, and Drainage Enhancements

Project Size: Approximately 1,300 Square Feet

Trinity Lutheran Church is more than just a place of worship; it’s a vibrant community center where families gather for daycare, children’s programs, worship services, concerts, and special events.

When the church needed a new roof, PB Roofing’s charitable initiative, PB Purpose, and Johns Manville teamed up to ensure the building could remain a safe and welcoming space for future generations.

Pastor Beate Storck observed, “Every step of the process, including discussing the scope of work and completing the project promptly, was handled with professionalism and care.”

Before the Project:

The secondary roof sections of the church were experiencing water ponding due to insufficient roof slope and aging drainage systems that allowed water to collect and penetrate the roof membrane, resulting in leaks inside the building. The church also needed a skylight fixture replaced and insulated.

Our Strategic Approach:

To meet the client’s specific needs, PB Roofing created a comprehensive replacement and repair plan that emphasized precision, durability, and efficiency. The project involved removing outdated systems and preparing the surfaces, followed by the installation of new tapered insulation, a sump, and a cricket system to improve drainage. An adhered EPDM membrane with heat-welded seams and Johns Manville specified flashing offered long-term protection, while new drains, edging, and skylight fixtures improved overall performance.

The Outcome:

• Worship services remain uninterrupted and safe for congregants year-round.
• Daycare and children’s programs can continue smoothly, giving peace of mind to families who depend on these services.
• Community events, concerts, and special gatherings will be held in a safe, comfortable environment.
• Outreach and fellowship programs that serve Tenafly and beyond can expand under a strong, dependable roof.

The Lesson:

“Our materials are designed to protect what matters most,” said Matt Allen of Performance Roofing Associates.

“Working with PB Roofing, we’re proud to ensure this project means more than just building a roof; we’re building hope and a safer, stronger future for the community.” Performance Roofing Associates is the representative for Johns Manville in Pennsylvania, New Jersey, and Delaware.

• Teaming up with industry leader Johns Manville to deliver more than just a construction project; it’s a meaningful investment in the community.
• Motivated by craftsmanship, compassion, and innovation, this partnership shows how strong collaborations can build even stronger communities.

Top 3 Relevant Knowledge Hub Blog Back Issues

• Restoring the Miracle Mile at Americana Manhasset (July 2025)
• 10 Steps to Choosing the Right Commercial Roofing Contractor (November 2024)
• 3 Ways to Identify & Solve Commercial Roof Leaks (October 2023)

Project: Americana Manhasset

Objective: Comprehensive Roof Restoration

Project Size: Approximately 26,200 Square Feet

Nestled along the famous stretch of Northern Boulevard known as the “Miracle Mile,” this upscale shopping destination needed a roofing solution that balanced precision, performance, and discretion. With many retail tenants and an open-air layout, every aspect of the project required careful planning and flawless execution.

Before the Project:

Before restoration began, the existing roof system had several significant issues. As one of the most luxurious shopping malls on Long Island, the mall features dozens of high-end brands, including Bottega Veneta, Cartier, Céline, Chanel, Dior, Fendi, Gucci, Hermès, Louis Vuitton, Prada, Tiffany & Co., and Versace.

• Exposed Utility Lines: Over 200 feet of vulnerable lines pose operational and aesthetic risks.
• Trapped Moisture in Existing Roof: Moisture was trapped in one of the existing roofs, and because of the many high-end stores with valuable merchandise, Americana Manhasset chose the WindSmart Vented Roof System, which allows the roof underneath to dry out gradually.
  • WindSmart is an Air-Sealed, Pressure-Equalized Commercial Roof System®: Designed to be more resistant to weather damage from wind, rain, and hail, and it can remove trapped moisture to prevent future tear-off. It also has the lowest life-cycle costs of any commercial roof system.
• Risk to High-Value Merchandise: Any breach or leak could damage luxury inventory.
• Aging Membrane System: Insufficient protection and reduction in energy efficiency.
• Flashing and Edge Failures: Risks of water intrusion from perimeter flashings and edge details.
• Unsealed Penetrations and Ventilation Gaps: Incomplete sealing allowed air and moisture to pass through, and inadequate venting worsened condensation risks.

Our Strategic Approach:

To meet the client’s performance, visual, and operational expectations, a tailored multi-scope restoration plan was implemented.

• Infrastructure Concealment & Safety: Utility lines were carefully rerouted and hidden, enhancing both safety and appearance.
• Substrate Stabilization: Gypsum cover board installation was used to reinforce the deck and create a solid base for the new membrane system. This also helped trap moisture and prepare for a seamless integration of new layers.
• Advanced Waterproofing & Protection: A high-performance, mechanically attached .060 TPO (Thermoplastic Polyolefin) membrane was installed directly over the existing EPDM Roofing System to ensure durability, UV resistance, and energy efficiency.
• WindSmart Integration: The project installed 24 WindSmart Wind Force Vents to significantly enhance air circulation and moisture management across the roof system. Air seals were installed at all existing penetrations in accordance with WindSmart’s specifications. Since no fasteners penetrate the decking, our Projects team focuses on preventing issues or leaks that could affect the high-end retail tenant spaces.
• Perimeter Defense: New flashing was carefully installed on parapets, edges, and curbs to prevent leak paths and support the WindSmart System by enhancing resistance to wind uplift. TPO pipe boots were also installed on all plumbing vents.

The Outcome:

• Watertight System: Moisture infiltration was prevented, safeguarding merchandise and maintaining the building envelope.
• Enhanced Aesthetics: Hidden utilities and a uniform membrane finish improved the center’s visual appeal.
• Energy efficiency: TPO membrane and WindSmart ventilation lowered cooling needs during summer months.
• Peace of Mind for Tenants & Owners: Strategic construction that avoids interior exposure or fastener penetration ensures uninterrupted operations.

The Lesson:

• Plan for Non-Disruption in Active Commercial Spaces
• Moisture Management Must Be Proactive, Not Reactive
• Aesthetic and Utility Improvements Can Be Simultaneously Achieved
• Modern Materials and Smart Ventilation Extend Roof Life
• Holistic Flashing and Edge Detailing Prevent Premature Failures

Top 3 Relevant Knowledge Hub Blog Back Issues

Protecting Commercial Roofing from Mold and Algae (January 2024)

Wind Effect on Commercial Roofs (December 2023)

Understanding a Commercial Roofing Warranty (April 2024)