Funky's Skate Center
TPO retrofit membrane installed over the existing metal roof
Project Overview
Funky's Skate Center at 100 Miller Circle in Harrisonburg is a family roller skating rink, a large open building where a dry roof matters for both the skating floor and the people on it. One 5,800 square foot section of the building has a low-slope metal roof, and that section also carries a rooftop solar array.
The owner needed a long-term roof on that section without giving up the solar system. That meant the array had to come off, the new roof had to go down, and the panels had to go back on the finished surface.
Job Photos
Before
Before
During
During
FinishedFinishedThe Challenge
The metal on this section showed its age. Before the work, rust was streaking along the panel ribs and fastener lines, and staining along the roof edge. Metal roofs like this one tend to leak at the laps, fasteners and edges as they age, and those were the areas we needed to cover.
The solar array was the bigger complication. Panels and racking sat on top of the area we needed to work on, so nothing could start until every panel was taken down, stacked and protected on the roof. They also had to stay out of the way of the crew while the new membrane was installed.
Our Solution
We removed all of the solar panels and staged them on the roof, installed a TPO retrofit system over the existing metal, and then reinstalled the panels on the new white membrane. The original metal roof stayed in place underneath as the deck for the new system.
- 1We took down every solar panel and stacked and wrapped them on the roof so they stayed protected during the work.
- 2We prepared the existing metal roof as the base for the retrofit system.
- 3We installed the TPO retrofit system across the 5,800 square foot section, working around the stacked panels as the membrane went down.
- 4We reinstalled the solar panels on their racking over the finished TPO roof.
Why This Approach
A TPO retrofit lets a building owner put a new single-ply roof over an existing metal roof instead of tearing the metal off. The metal stays in place as the structure, so there is no tear-off debris and the building stays closed in. TPO is a white, heat-welded membrane, which means the seams are fused rather than glued, and it gives a smooth, continuous surface over the ribs, laps and fasteners where old metal roofs usually leak. For a roof that carries solar, putting the long-term roof under the array now avoids having to remove the panels again for a roof problem later.
Results
- 5,800 square feet of metal roof covered with a new TPO retrofit system
- Existing metal panels left in place, with no tear-off
- All solar panels removed, protected on the roof and reinstalled
- White membrane now sits under the solar array
Common Questions
Can a TPO roof be installed over an existing metal roof?
Yes. A TPO retrofit is a common way to re-roof a low-slope metal building. The metal stays in place as the deck, the system is built up to give the membrane a flat, supported surface, and the TPO is fastened and heat-welded over it. The roof needs to be structurally sound, so we check the metal before recommending it.
What happens to rooftop solar panels when a roof is replaced?
The panels and usually the racking have to come off the area being roofed. They are taken down, stored safely, and reinstalled once the new roof is finished. Planning this with the solar owner or installer ahead of time keeps the system protected and avoids surprises with wiring and attachments.
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