Built-Up Roofing (BUR) Systems
The original flat roofing system with over 100 years of proven performance. Multiple layers of waterproof protection for commercial buildings requiring maximum durability and long-term reliability.
What is Built-Up Roofing (BUR)?
Built-up roofing, commonly known as BUR or "tar and gravel roofing," is the grandfather of modern flat roofing systems. This time-tested technology has protected commercial buildings for over 120 years, earning its reputation as one of the most reliable and durable flat roofing options available. Despite the emergence of modern single-ply membrane systems, built-up roofing remains a preferred choice for building owners who prioritize long-term durability and proven performance over installation speed.
The term "built-up" refers to the construction method: multiple layers of roofing materials are literally built up on the roof deck to create a thick, seamless, waterproof membrane. A typical BUR system consists of alternating layers of bitumen (either hot-applied asphalt or coal tar pitch) and reinforcing fabrics called roofing felts or ply sheets. The system is then topped with a protective surfacing layer, traditionally gravel or crushed stone, though modern options include mineral granules, reflective coatings, or cap sheets.
The multi-layer construction is what gives built-up roofing its exceptional durability and redundancy. While a single-ply membrane relies on one layer for waterproofing, a 4-ply BUR system provides four separate waterproof barriers. If one layer is compromised by damage or wear, the underlying layers continue protecting the building. This redundancy is why many building owners with critical operations—hospitals, data centers, manufacturing facilities—continue choosing built-up roofing despite newer alternatives.
History and Evolution of Built-Up Roofing
The history of built-up roofing traces back to the mid-1800s when the Industrial Revolution created demand for large, flat-roofed commercial and industrial buildings. Early flat roofs used simple tar-soaked cotton or jute fabrics, but these primitive systems had limited durability. The development of coal tar pitch processing in the 1840s-1850s provided a superior waterproofing material, and by the 1870s, the basic BUR system we recognize today had emerged.
The early 20th century saw significant refinements in BUR technology. Organic felts made from cotton rags, paper, or wood fibers became standardized. Asphalt bitumen, a byproduct of petroleum refining, became increasingly popular as an alternative to coal tar due to lower cost and wider availability. The introduction of gravel surfacing provided UV protection and fire resistance, making BUR suitable for a wider range of applications.
The post-World War II building boom of the 1950s and 1960s established built-up roofing as the dominant commercial flat roofing system in America. During this period, fiberglass felts began replacing organic felts, offering improved dimensional stability, rot resistance, and fire performance. Hot-mopped asphalt BUR became the industry standard, with millions of square feet installed annually on schools, hospitals, office buildings, and industrial facilities.
The 1970s brought new challenges with the energy crisis prompting demand for better-insulated roofs. BUR systems evolved to incorporate rigid foam insulation boards, improving building energy efficiency while maintaining waterproofing integrity. Modified bitumen systems, using polymer-enhanced asphalt in pre-manufactured sheets, emerged as a hybrid technology combining BUR durability with easier installation.
The 1980s and 1990s saw the rise of single-ply membranes (TPO, PVC, EPDM), which offered faster installation and lower labor costs. While single-ply systems captured significant market share, built-up roofing retained loyal advocates who valued its proven track record and superior durability. Today, BUR represents approximately 15-20% of the commercial flat roofing market, primarily on buildings where long-term performance outweighs initial cost considerations.
Modern built-up roofing incorporates advanced materials including polyester and fiberglass felts, SBS and APP modified bitumen products, and high-performance reflective coatings. Cold-applied adhesive systems reduce installation emissions and safety concerns associated with hot asphalt. These innovations ensure built-up roofing remains relevant and competitive in the 21st century commercial roofing market.
Components of Built-Up Roofing Systems
Understanding the components of a built-up roofing system helps building owners make informed decisions about specifications, maintenance, and repairs. Each layer serves a specific purpose in the overall waterproofing and protection system.
Roof Deck
The structural substrate supporting the roofing system. Common materials include concrete, steel decking, plywood, or oriented strand board (OSB). The deck must be structurally sound, clean, dry, and properly sloped for drainage. Deck preparation is critical—moisture, contamination, or structural defects cause premature roof failure.
Insulation Layer
Rigid insulation boards installed between the deck and roofing membrane. Common materials include polyisocyanurate (polyiso), expanded polystyrene (EPS), and extruded polystyrene (XPS). Insulation improves energy efficiency and provides a smooth substrate. Tapered insulation creates slope for drainage on flat decks.
Base Sheet
The first ply of the BUR system, mechanically fastened or adhered to the insulation. Base sheets are typically heavy-duty fiberglass or polyester felts that provide a stable foundation for subsequent layers. Proper base sheet attachment is critical for wind uplift resistance and preventing membrane delamination.
Bitumen (Asphalt or Coal Tar)
The waterproofing agent that bonds the plies together and provides the primary moisture barrier. Hot-applied asphalt (400-450°F) is most common. Coal tar pitch offers superior waterproofing but limited availability. Cold-applied adhesives provide a modern alternative without hot kettles. Bitumen quality and application temperature are critical.
Ply Sheets (Felts)
Reinforcing fabrics that provide strength, dimensional stability, and additional waterproofing. Modern BUR uses fiberglass or polyester felts rather than organic materials. Each ply is mopped with hot bitumen and rolled into place, creating laminated layers. Most BUR systems include 3-5 ply sheets depending on durability requirements.
Surfacing Materials
The protective top layer that shields the membrane from UV radiation, physical damage, and weathering. Gravel (aggregate) is traditional, providing weight, fire resistance, and excellent UV protection. Mineral-surfaced cap sheets offer a cleaner appearance. Reflective coatings improve energy efficiency but require periodic reapplication.
Types of Built-Up Roofing Systems
Built-up roofing systems are categorized primarily by the type of bitumen used and the application method. Each type has specific advantages, ideal applications, and considerations for installation and maintenance.
Asphalt Built-Up Roofing (Hot-Applied)
The most common BUR system, using hot-applied asphalt bitumen heated in kettles to 400-450°F and mopped between ply sheets. Asphalt BUR offers excellent waterproofing, good durability, and competitive pricing. It performs well in most climates and is compatible with various surfacing options including gravel, cap sheets, and coatings.
Advantages:
- Lower cost than coal tar systems
- Widely available materials and expertise
- Good performance in varied climates
- Compatible with all surfacing types
- Easier to repair than coal tar
Considerations:
- Softens at high temperatures (160°F+)
- Less resistant to ponding water
- No self-healing properties
- Hot application safety requirements
- Strong odor during installation
Coal Tar Built-Up Roofing
The premium BUR option, using coal tar pitch derived from coking coal. Coal tar BUR offers superior waterproofing due to its "cold flow" property—the material slowly moves to self-heal minor punctures and cracks. It resists ponding water exceptionally well, making it ideal for roofs with drainage challenges. Coal tar systems can last 40+ years with proper maintenance.
Advantages:
- Superior waterproofing performance
- Self-healing properties (cold flow)
- Excellent resistance to ponding water
- Longest lifespan (40+ years possible)
- Proven track record exceeding 100 years
Considerations:
- Higher cost than asphalt systems
- Limited availability of materials
- Strong odor and fumes during installation
- Cannot mix with asphalt products
- Specialized repair requirements
Cold-Applied Built-Up Roofing
Modern BUR systems using cold-applied adhesives rather than hot bitumen. These systems eliminate the need for asphalt kettles, reducing fire risk, air quality concerns, and installation hazards. Cold-applied BUR uses solvent-based or water-based adhesives to bond ply sheets, offering comparable performance to traditional hot-mopped systems in many applications.
Advantages:
- No hot kettles or open flames
- Reduced safety risks
- Lower fumes and odor
- Easier installation in occupied buildings
- Better for urban/sensitive locations
Considerations:
- Higher material costs
- Longer cure times than hot systems
- Temperature-sensitive application
- Some adhesives contain VOCs
- Shorter track record than hot BUR
Built-Up Roofing vs Modern Single-Ply Systems
The choice between built-up roofing and single-ply membranes (TPO, PVC, EPDM) is one of the most important decisions commercial building owners face. Both are proven, reliable systems with distinct advantages. Understanding these differences helps match the right roofing system to your building's specific needs, budget, and operational requirements.
| Factor | Built-Up Roofing (BUR) | Single-Ply (TPO/PVC/EPDM) |
|---|---|---|
| Durability | Exceptional - multiple redundant layers | Good - single layer waterproofing |
| Lifespan | 20-40 years | 15-30 years |
| Initial Cost | Higher ($6-12/sq ft) | Lower ($5-10/sq ft) |
| Installation Speed | Slower - multiple layers | Faster - single membrane |
| Weight | Heavy (with gravel surfacing) | Lightweight |
| Puncture Resistance | Excellent | Good to Moderate |
| Energy Efficiency | Moderate (gravel) to Good (coatings) | Excellent (white membranes) |
| Maintenance | More involved inspections | Easier visual inspections |
Choose Built-Up Roofing When: Your building requires maximum durability and can support additional weight. BUR excels for buildings with heavy foot traffic (maintenance access, rooftop equipment), facilities where roof failure would be catastrophic (hospitals, data centers), and owners prioritizing long-term value over initial cost. The redundant waterproofing layers provide peace of mind for critical operations.
Choose Single-Ply Membranes When: Energy efficiency and reflectivity are priorities, structural weight capacity is limited, fast installation is required to minimize business disruption, or budget constraints favor lower initial costs. TPO and PVC systems offer excellent performance for most commercial applications, particularly retail, office, and light industrial buildings.
Advantages of Built-Up Roofing
Redundant Waterproofing
Multiple bitumen layers mean water must penetrate 3-5 barriers to cause damage. If one layer fails, others continue protecting the building.
Proven Track Record
Over 120 years of documented performance. No guesswork about long-term durability—BUR systems have proven they last.
Superior Puncture Resistance
The thick, multi-layer construction resists damage from dropped tools, foot traffic, and rooftop equipment better than thin single-ply membranes.
Seamless Waterproof Membrane
Unlike seamed single-ply systems, BUR creates a continuous, seamless waterproof surface across the entire roof area.
Thermal Performance
The mass of BUR systems provides thermal stability, reducing temperature fluctuations and thermal shock on the roof structure.
Fire Resistance
Gravel-surfaced BUR achieves Class A fire ratings. The aggregate surfacing provides excellent fire resistance without additional treatments.
Simple Repairs
Damaged areas can be patched by adding new layers of felt and bitumen—no specialized welding equipment or difficult seam work required.
Long Lifespan
Properly installed and maintained BUR roofs last 20-30 years typically, with coal tar systems potentially reaching 40+ years.
Disadvantages and Considerations
While built-up roofing offers significant advantages, it is not the ideal solution for every building. Understanding the limitations helps ensure you select the right roofing system for your specific situation.
Weight Considerations
Gravel-surfaced BUR systems can weigh 6-8 pounds per square foot or more—significantly heavier than single-ply alternatives at 0.5-1.5 lbs/sq ft. Buildings with limited structural capacity may require costly reinforcement or must choose lighter roofing options. Always verify structural adequacy before specifying BUR.
Longer Installation Time
Building up multiple layers takes more time than rolling out single-ply membranes. Installation typically takes 2-3 times longer than equivalent single-ply projects, meaning more labor cost and longer business disruption. Hot weather can also limit installation hours for worker safety.
Installation Conditions
Hot-applied BUR requires asphalt kettles with open flames, creating fire risk and strong odors. Cold weather limits application (typically above 40-50°F). These factors can delay projects and may be problematic for occupied buildings or urban locations with air quality concerns.
Leak Detection Challenges
When leaks occur, water can travel between layers before appearing inside the building, making the leak source difficult to locate. Gravel surfacing further obscures visual inspection. Infrared scanning or flood testing may be needed to pinpoint leak locations.
Higher Initial Cost
BUR typically costs 20-40% more than basic single-ply installations due to material quantity and labor intensity. While lifecycle costs often favor BUR, the higher upfront investment can be a barrier for budget-constrained projects or buildings with limited remaining useful life.
Decreasing Contractor Expertise
As single-ply systems dominate the market, fewer roofing contractors maintain BUR expertise. Finding qualified installers can be challenging in some areas. Poor installation significantly reduces BUR performance, making contractor selection critical.
Built-Up Roofing for Commercial Buildings
Built-up roofing remains a preferred choice for many commercial roofing applications where durability and reliability outweigh concerns about installation time or weight. Understanding which building types benefit most from BUR helps owners make informed roofing decisions.
Ideal Applications for BUR
Hospitals and Healthcare Facilities: Roof leaks can compromise sterile environments, damage expensive equipment, and disrupt critical patient care. BUR's redundant waterproofing layers provide the reliability healthcare facilities demand. Many hospitals specify BUR for operating room areas and imaging suites where even minor leaks would be catastrophic.
Data Centers and Technology Facilities: Computing equipment cannot tolerate water intrusion. The multi-layer protection of BUR provides peace of mind for facilities where downtime costs thousands of dollars per minute. The thermal mass also helps stabilize rooftop temperatures, benefiting HVAC efficiency.
Manufacturing and Industrial Buildings: Heavy foot traffic, equipment installations, and maintenance activities can damage lighter roofing systems. BUR's superior puncture resistance handles industrial abuse. Chemical resistance (especially coal tar) suits facilities with rooftop exhaust or process emissions.
Warehouses and Distribution Centers: Large, simple roof areas are cost-effective for BUR installation. The long lifespan and low maintenance requirements suit facilities focused on operational efficiency. Gravel surfacing provides excellent fire resistance for buildings storing combustible materials.
Schools and Institutions: Long-term ownership and limited budgets for frequent replacements favor BUR's durability. The proven track record reassures administrators responsible for building stewardship. Many schools have BUR roofs installed decades ago still performing well today.
BUR and Rooftop Equipment
Commercial buildings increasingly feature rooftop HVAC units, solar panels, satellite dishes, and telecommunications equipment. BUR handles these installations well due to its puncture resistance and ability to accommodate penetrations. The thick membrane can be cut and properly detailed around equipment curbs without compromising waterproofing integrity. When equipment must be replaced or relocated, BUR can be patched and repaired without full membrane replacement.
Built-Up Roofing in Coastal South Carolina
The Myrtle Beach area and South Carolina Lowcountry present unique challenges for commercial roofing systems. High humidity, salt air exposure, intense UV radiation, heavy rain events, and hurricane threats require careful material selection and installation practices. Built-up roofing can perform exceptionally well in this environment when properly specified and installed.
Coastal Climate Considerations
Hurricane and Wind Resistance: Gravel-surfaced BUR provides excellent wind uplift resistance due to weight—the aggregate ballast helps anchor the membrane against high winds. Properly attached BUR systems can meet Miami-Dade hurricane requirements. However, loose gravel can become projectiles in extreme winds; consider alternative surfacing for high-velocity hurricane zones (HVHZ).
Salt Air and Moisture: Unlike metal roofing components that can corrode, BUR materials resist salt air degradation. The waterproof bitumen layers prevent moisture infiltration. Coal tar BUR is particularly effective in high-moisture coastal environments due to superior waterproofing properties and resistance to ponding water.
UV Exposure: South Carolina's intense sunshine accelerates roof material degradation. Gravel surfacing provides excellent UV protection for the underlying bitumen. Reflective coatings can enhance energy efficiency while protecting the membrane. Mineral-surfaced cap sheets offer a middle-ground solution with good UV resistance and cleaner appearance.
Heavy Rainfall: Coastal SC receives 50-55 inches of rain annually, often in intense downpours. BUR's seamless waterproof membrane excels at handling heavy rain when drainage is adequate. Proper slope and clear drains are critical—ponding water remains the leading cause of premature BUR failure in humid climates where evaporation is slow.
Local BUR Recommendations
For Myrtle Beach commercial buildings, we typically recommend minimum 4-ply asphalt BUR systems with proper tapered insulation for drainage. Coal tar BUR is excellent for buildings with historically problematic drainage. Reflective coatings over smooth-surfaced BUR provide energy savings while maintaining waterproofing integrity. Regular maintenance inspections after tropical storms help catch damage before it causes interior problems.
Built-Up Roofing Installation Process
Quality installation is critical to BUR performance. The multi-layer construction requires careful attention to each step—mistakes become embedded in the roof system and may not manifest as problems until years later. Understanding the installation process helps building owners evaluate contractor quality and project progress.
Roof Deck Preparation
The existing roof surface is prepared for new installation. For re-roofing projects, this typically means complete tear-off of existing materials down to the structural deck. The deck is inspected for damage, moisture, and structural integrity. Repairs are made as needed. The deck must be clean, dry, and smooth before proceeding.
Vapor Barrier Installation
Where required by climate conditions (typically in air-conditioned buildings), a vapor barrier is installed to prevent condensation within the roof assembly. This prevents moisture from migrating from the conditioned interior into the insulation layer.
Insulation Installation
Rigid insulation boards are mechanically fastened or adhered to the roof deck. Multiple layers may be installed with staggered joints. Tapered insulation creates slope for drainage on flat structural decks. Cover boards (high-density insulation or gypsum) may be installed over softer insulation to improve puncture resistance.
Base Sheet Application
The first ply sheet is mechanically fastened or fully adhered to the substrate. This base sheet anchors the subsequent membrane layers to the building. Proper attachment is critical for wind uplift resistance. Seams are lapped and secured per manufacturer specifications.
Hot Bitumen and Ply Application
For hot-applied systems, asphalt is heated in rooftop kettles to 400-450°F and pumped or carried to the application area. Hot bitumen is mopped onto the surface, and ply sheets are immediately rolled into the hot asphalt. This process is repeated for each ply (typically 3-4 additional plies). Proper bitumen temperature and coverage are critical for adhesion.
Flashing Installation
All roof penetrations (pipes, drains, equipment curbs), perimeter edges, and transitions require special detailing with flashing materials. Multiple layers of felt and bitumen are applied to create watertight seals. Metal edge details and counterflashing are installed. Proper flashing is critical—most leaks occur at these transition points.
Surfacing Application
The final flood coat of hot bitumen is applied, followed immediately by the surfacing material. For gravel surfacing, aggregate is spread and embedded into the hot bitumen. Cap sheets are rolled into hot bitumen and seams are sealed. Reflective coatings are applied after the membrane has cured.
Quality Inspection and Cleanup
The completed roof is inspected for proper coverage, adhesion, surfacing, and flashing details. Core samples may be taken to verify ply count and bitumen content. All equipment and debris are removed. Documentation including photos, test reports, and warranty information is provided.
Lifespan and Maintenance Requirements
Built-up roofing systems reward attentive maintenance with exceptional longevity. While BUR can survive neglect better than some roofing types due to its robust construction, proper maintenance significantly extends service life and prevents costly emergency repairs.
Expected Lifespan by System Type
- Asphalt BUR (3-ply): 15-20 years typical
- Asphalt BUR (4-ply): 20-25 years typical
- Asphalt BUR (5-ply): 25-30 years typical
- Coal Tar BUR: 30-40+ years typical
These lifespans assume proper installation and reasonable maintenance. Neglected roofs may fail in half the expected time, while well-maintained systems often exceed projections. Climate plays a significant role—roofs in harsh coastal environments like Myrtle Beach may have reduced lifespans compared to protected inland locations.
Maintenance Best Practices
Bi-Annual Inspections: Schedule professional inspections every spring and fall. Inspectors check membrane condition, drainage function, flashing integrity, and surfacing condition. Post-storm inspections are essential in hurricane-prone areas.
Drain Maintenance: Keep roof drains, scuppers, and gutters clear of debris. Clogged drainage causes ponding water—the number one enemy of BUR systems. Monthly drain checks during fall leaf season prevent problems.
Prompt Repairs: Address issues when they are small. A minor blister or crack repaired promptly costs a fraction of the water damage that results from delayed maintenance. BUR repairs are straightforward—new layers of felt and bitumen patch damaged areas.
Traffic Control: Establish designated walkways for regular roof access. Avoid dragging equipment across the membrane. Use walk pads in high-traffic areas to protect the surfacing and underlying membrane.
Vegetation Control: Remove vegetation growth promptly. Roots can penetrate membrane layers, and accumulated organic matter retains moisture and accelerates deterioration.
BUR Repair vs Replacement: Making the Right Decision
Determining whether to repair or replace a built-up roof requires evaluating multiple factors including age, condition, budget, and long-term building plans. The right choice balances immediate costs against future performance and risk.
When to Repair
Repair makes sense when the roof has substantial remaining service life (less than 50% of expected lifespan), damage is localized rather than widespread, the roof structure and insulation remain sound, and repair costs are less than 30% of replacement costs. Common repairable issues include isolated blisters, localized alligatoring, flashing failures, and puncture damage.
When to Replace
Replacement is advisable when the roof has exceeded its expected service life, multiple leaks indicate widespread membrane failure, insulation is saturated with moisture, repairs in recent years exceed 50% of replacement cost, or the roof no longer meets code or insurance requirements. A professional roof assessment can determine whether underlying components (insulation, deck) can be reused or require replacement.
Roof Restoration Option
For roofs in fair condition, restoration coatings can extend service life by 10-15 years at 30-50% of replacement cost. This involves cleaning the existing membrane, repairing defects, and applying a reflective elastomeric coating. Restoration is viable when the existing membrane is basically sound but showing age. It is not appropriate for roofs with significant moisture infiltration or structural issues.
Cost Factors for Built-Up Roofing
Built-up roofing costs vary significantly based on system specifications, project conditions, and regional factors. Understanding these variables helps building owners develop realistic budgets and evaluate contractor proposals.
Number of Plies
More layers = higher cost but longer lifespan. A 3-ply system may cost 20-30% less than a 5-ply system but provide shorter service life.
Bitumen Type
Coal tar systems cost 15-25% more than asphalt but offer superior performance and longer lifespan. Hot-applied costs less than cold-applied systems.
Surfacing Material
Gravel is most economical. Mineral cap sheets cost more but provide a cleaner look. Reflective coatings add cost but improve energy efficiency.
Insulation Requirements
Thicker insulation for better energy efficiency adds material cost. Tapered insulation for drainage costs more than flat installation.
Roof Complexity
Multiple penetrations, complex shapes, and numerous detail areas increase labor time and flashing material requirements.
Access and Logistics
Difficult access, material hoisting requirements, and occupied building constraints affect labor productivity and costs.
Tear-Off Requirements
Complete tear-off to deck adds significant cost versus recovering over existing roofing. Disposal fees vary by region.
Warranty Coverage
Extended manufacturer warranties require certified installation and premium specifications, adding to total project cost.
Request a Custom Quote
Every commercial roofing project has unique requirements affecting cost. Contact Weather Shield Roofing for a comprehensive roof assessment and detailed proposal tailored to your building's specific needs and budget.
Frequently Asked Questions About Built-Up Roofing
What is built-up roofing (BUR)?
Built-up roofing (BUR) is a time-tested flat roofing system consisting of alternating layers of bitumen (asphalt or coal tar) and reinforcing fabrics called roofing felts or ply sheets. The system is topped with a protective surfacing such as gravel, mineral granules, or a reflective coating. BUR systems typically include 3-5 layers, creating a thick, durable, waterproof membrane that has protected commercial buildings for over 100 years.
How long does a built-up roof last?
A properly installed and maintained built-up roof typically lasts 20-30 years, with some coal tar BUR systems lasting 40+ years. Lifespan depends on the number of plies (more layers = longer life), quality of installation, climate conditions, and maintenance frequency. In coastal South Carolina, regular inspections and prompt repairs help BUR roofs achieve maximum longevity despite humidity and salt air exposure.
Is built-up roofing better than single-ply membrane?
Neither is universally "better" - each has advantages for different applications. BUR offers superior puncture resistance, redundant waterproofing (multiple layers), proven long-term performance, and excellent durability for heavy foot traffic. Single-ply membranes (TPO, PVC, EPDM) are lighter weight, faster to install, more reflective for energy savings, and easier to repair. BUR excels for buildings requiring maximum durability and where weight is not a concern.
What is the difference between asphalt and coal tar BUR?
Asphalt BUR uses petroleum-based bitumen, is more common, less expensive, and suitable for most applications. It softens at high temperatures but performs well in most climates. Coal tar BUR uses coal tar pitch, offers superior waterproofing and self-healing properties (minor punctures seal themselves), and resists ponding water better. Coal tar is more expensive, has stronger odor during installation, and is ideal for roofs with drainage challenges or extreme moisture exposure.
Can you install built-up roofing over an existing roof?
Sometimes, depending on the existing roof condition and local building codes. If the current roof is in fair condition without moisture damage, a BUR system can potentially be installed over it (called a recover or overlay). However, building codes typically limit total roof layers to two. Most commercial re-roofing projects require complete tear-off for proper inspection of the roof deck, installation of new insulation, and warranty coverage.
What causes built-up roofing to fail?
Common BUR failure causes include: improper installation (poor adhesion between layers, insufficient bitumen), ponding water (standing water degrades materials), lack of maintenance (clogged drains, debris accumulation), thermal cycling damage (expansion/contraction cracks), UV degradation (on BUR without gravel surfacing), and physical damage from foot traffic or dropped equipment. Most failures are preventable with quality installation and regular maintenance.
How much does built-up roofing cost?
Built-up roofing typically costs $6-12 per square foot installed, depending on the number of plies, bitumen type (asphalt vs coal tar), surfacing material, insulation requirements, and project complexity. A 10,000 sq ft commercial BUR roof might range from $60,000-$120,000. While BUR has higher initial costs than some single-ply options, its exceptional durability and long lifespan often provide better long-term value for buildings requiring robust protection.
Is built-up roofing good for coastal areas?
Yes, BUR performs well in coastal environments when properly specified and installed. The multiple waterproof layers provide excellent protection against wind-driven rain. Gravel surfacing protects against UV degradation and provides weight for wind uplift resistance. Coal tar BUR is particularly good for coastal areas due to superior moisture resistance. The main coastal consideration is ensuring proper drainage to prevent ponding water, which is more damaging in humid climates.
What maintenance does built-up roofing require?
BUR requires semi-annual inspections (spring and fall), plus post-storm checks. Maintenance includes: clearing drains and scuppers, removing debris and vegetation, inspecting for blisters, cracks, and open seams, checking flashing conditions, and addressing ponding water issues. Minor repairs should be made promptly before they spread. Professional maintenance programs significantly extend BUR roof life and are often required to maintain warranty coverage.
Can solar panels be installed on built-up roofing?
Yes, solar panels can be installed on BUR roofs using ballasted racking systems (weighted down, no penetrations) or attached systems with properly flashed penetrations. BUR is actually well-suited for solar due to its puncture resistance and ability to support additional weight. Consider timing solar installation with roof replacement or when the roof has sufficient remaining life. We coordinate with solar installers to ensure proper installation that maintains roof warranty coverage.
Expert Built-Up Roofing Installation and Repair
Weather Shield Roofing provides professional built-up roofing services for commercial buildings throughout Myrtle Beach and coastal South Carolina. Our experienced crews deliver quality BUR installations backed by comprehensive warranties.
Serving Myrtle Beach, North Myrtle Beach, Conway, Surfside Beach, and surrounding areas