A regional cold storage operator with a 75,000 sqft refrigerated distribution facility in Henderson County, NC engaged Southeast Commercial Roofing to replace a 20+ year EPDM roof with documented seam failures. The project completed in 10 working days with all 8 freezer bays online the entire time. Client name anonymized for confidentiality.
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The facility's existing EPDM had reached end-of-life — recurring seam failures over the cold-side freezer bays were producing condensation infiltration above product. The operator needed a roof replacement that protected refrigeration uptime as the non-negotiable constraint. Standard tear-off would have required a multi-week shutdown of at least two freezer bays. Our phased approach kept all 8 bays online through the install.
A cold storage roof replacement isn't a roofing job — it's a refrigeration uptime job that happens to involve a roof. The sequencing below was built around keeping freezer bay temperatures stable while the membrane changed over.
Drone roof scan, infrared moisture survey on the existing EPDM, core cuts at 9 sample points to verify insulation condition, and load calc against the existing steel deck. Refrigeration ops walked the schedule with our PM to lock down a phased approach that kept all 8 freezer bays online.
Crew, manlift, kettle, and material staged on the south parking lot away from receiving lanes. Negative-pressure containment at the loading dock to keep insulation dust off product. Daily air-quality logs filed with the facility QA manager.
EPDM and ballast removed in 10,000 sqft sections to maintain a watertight envelope each night. Wet insulation flagged from the pre-survey was replaced before new insulation went down. Saturated decking — none found, decking integrity confirmed clean by the facility engineer.
Two layers of polyiso (staggered seams) plus tapered ISO crickets to redirect ponding away from new drains. 80-mil TPO installed with bonding adhesive on the entire field, hot-air welded seams, GAF-trained foreman QC'd every weld with a probe. 22 new internal drains tied into existing scuppers to handle WNC monsoon-pattern rain events.
All 47 penetrations re-flashed with prefab boots. New refrigerant line supports installed by our subcontractor. TPO walkway pads laid on the regular access path between condenser units to protect the membrane during quarterly maintenance.
GAF field rep walked the roof and signed off on warranty registration the same day. Facility maintenance and operations leads received the close-out packet: drone after-shots, weld map, photo log of every penetration, and warranty paperwork in their hands before crew demobed.
All 8 freezer bays stayed online through the entire 10-day install. Phased tear-off + nightly watertight envelope made it possible.
From mobilization to warranty registration. Original GC quote was 18 days. We delivered in 10 by sequencing tear-off and install in parallel sections.
GAF 20-year NDL (no dollar limit) on materials and labor. Plus our 5-year workmanship warranty on top.
Tapered insulation + 22 new drains reduced ponding-water area by 31% vs original drainage layout. Verified via 24-hr post-rainfall drone survey.
Cold storage operators treat facility specs as competitive intelligence. We anonymize project details — client name, exact address, operational specifics — by default unless the client explicitly waives that. The technical and operational details above are accurate to the actual project as completed in Q1 2026 in Henderson County, NC. Photo, drone footage, and reference contact available under NDA on request from qualified facility owners or insurance professionals.
Considering a similar project? Cold storage, food processing, pharma, and any temperature-sensitive industrial roof requires a different sequencing approach than a standard commercial reroof. Talk to our PMs about phased install options that protect operational uptime.
Tell us about the facility. We deliver a detailed, line-item bid within 48 hours — no pressure, no up-sell, real pricing for the roof you actually need.
