Bayfront Distribution Roof Replacement
Complete tear-off and replacement of a 148,000 SF low-slope roof over an occupied distribution building, replacing a failed ballasted EPDM system with a fully adhered 60-mil TPO assembly engineered for Florida Building Code wind uplift pressures. The roofing subcontractor needed a Division 07 estimate with fastener patterns by zone priced in 48 hours.
Location
Jacksonville, FL
Size
148,000 SF TPO
Estimated value
$2.3M
Estimate turnaround
48 hours
Scope estimated
What we measured and priced
- 148,000 SF of ballasted EPDM tear-off with 820 tons of stone ballast removed and 1,400 CY of debris hauled
- 148,000 SF of 2 layers of polyiso at R-30 with 1/2-inch gypsum cover board, mechanically fastened by wind zone
- 148,000 SF of fully adhered 60-mil TPO with enhanced perimeter and corner zones totaling 26,000 SF
- 1,620 LF of parapet base flashing, 1,620 LF of new coping and 640 LF of expansion joint cover
- 212 pipe and curb penetrations, 48 RTU curbs reflashed and 14 new walkway pad runs
- 22 roof drains with new strainers and 22 overflow scuppers added to meet current code
- 36 skylight replacements and 24 smoke vent reflashings
- Metal deck repair allowance of 4,800 SF with 1,100 LF of edge nailer replacement
The estimating challenge
A ballasted EPDM tear-off hides its real cost in the ballast: 820 tons of stone had to come off a 148,000 SF roof over an active warehouse, with no interruption to dock operations below and daily tie-in to keep the building dry during Florida's afternoon storm season. The new assembly's fastening pattern changed between field, perimeter and corner zones, and the perimeter zone width depended on the building height and parapet geometry. Deck condition under the ballast was unknown. The subcontractor needed a bid in two days with a documented basis for the deck repair allowance.
The result
LEEDS took off the roof by wind zone, calculating the perimeter and corner zone widths from the building dimensions and applying the manufacturer's fastener density for each, so the insulation and cover board fastener counts were exact. Ballast removal was priced with a vacuum truck production rate and daily tie-in labor over a 7-week schedule. The deck repair allowance was set at 3.2% of roof area from core cut and infrared survey data. The subcontractor bid $2.3M and was awarded the roof. Actual deck repair came in under the allowance, and the job finished without a weather-related interior leak.
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