Sample project

Fabrication shop SBS replacement after hail in Nisku

A 42,000 sq ft fabrication shop punctured by hail, made watertight the same day and replaced with 2-ply SBS.

Overview

A summer hailstorm left a working fabrication shop with leaks over its welding bays and an insurance claim to prove. This sample shows how we move from emergency response to documented replacement.

Same-day response

Active leaks stopped the afternoon of the call.

Claim documented

Survey, cores and photo report supplied to the adjuster.

Shop kept running

Fabrication continued below throughout the work.

Hailstones bouncing on a commercial roof membrane

The problem

A July 2024 hailstorm bruised and punctured the shop's single-ply roof across most of its surface. Leaks showed up within days over the welding bays and the office mezzanine. The owner needed two things quickly: a watertight roof, and documentation strong enough to support an insurance claim.

The approach

Our crew made temporary repairs the same afternoon to stop the active leaks. We then documented the damage: a grid survey of the whole roof, scaled photos of each impact zone, nine core samples, and a written report for the adjuster. The insurer approved full replacement after reviewing it.

For the new roof we specified 2-ply SBS. It is the regional workhorse for good reason. Two plies give real thickness against hail and punctures, a granulated cap stands up to regular maintenance foot traffic, and the system stays tough through a long Alberta winter. A high-density cover board under the membrane adds impact resistance.

Torch-on work over a fabrication shop calls for tight hot work control. Welding continued in the bays below, so we coordinated our hot work permits with the shop's own, kept a fire watch on the roof during and after torching, and used a self-adhered base sheet at the wood nailers and around the exhaust fan curbs, where an open flame is the wrong tool.

The result

Replacement was complete in five weeks. The roof stayed dry through the following spring melt, and the replacement was covered under the owner's property policy. The shop did not lose a single production day to the roofing work.

The warranty issued

The owner received a 15-year ARCA Warranty Certificate, backed by ARCA Warranty Ltd from year 3, along with the manufacturer's 15-year warranty and our 10-year workmanship warranty. An independent ARCA inspector checked the roof during application, and the year-2 follow-up inspection is booked for 2026. The warranty file includes the hail report, in case the owner ever needs to show the roof's history.

Scope of work

Item 01: Emergency temporary repairs on the day of the call
Item 02: Hail damage survey with photos, nine core samples and a written report for the insurer
Item 03: Tear-off of the damaged single-ply roof and wet insulation
Item 04: New tapered polyiso and high-density cover board
Item 05: 2-ply SBS: torch-applied base and granulated cap
Item 06: Self-adhered base sheet at wood nailers and exhaust fan curbs

Questions

What facility managers ask us

Ask your own

Why SBS rather than another single-ply roof?

Two plies of SBS with a granulated cap give more thickness against hail and punctures. That mattered on a roof that had just been wrecked by a storm and sees regular maintenance traffic.

Can torch-on roofing be installed over a working shop?

Yes, with coordinated hot work permits, a fire watch, and cold-applied or self-adhered products at combustible details. That is how this project was run.