Case Study

Industrial Roofing Replacements

OVERVIEW

T&M has managed industrial roof replacements across a wide range of heavy manufacturing and food processing environments. Some of which include active food processing plants, metal casting foundries, electrical power systems manufacturers, and steel production facilities. In each case, protecting what sits below the roof is as critical as the roofing work itself.

THE CHALLENGE

Across industrial facilities of all types, aging roof systems reach end of serviceable life and create exposure to leaks, energy loss, and compliance gaps. Every facility presents a different solution based on its existing system, structural constraints, and the active operations running below.

None of these facilities can afford disruption. Production has to continue throughout construction.

Common Constraints T&M Design Navigates:

Food production below requires full protection from debris, moisture, and contamination
Live foundry operations require daily scheduling coordination around active metal casting
Legacy coal tar pitch roofs require replication due to structural constraints, including special permitting
Insulation additions for energy code compliance requires safely raising mechanical equipment
Fall protection required at all penetrations and leading edges throughout each project
Temporary waterproofing installed each night to protect open decks from precipitation
Materials must be distributed across the roof surface to stay within structural load limits

HOW T&M DESIGN APPROACHES THIS WORK

T&M Design serves as construction and project manager across a variety of facilities, covering scope development, contractor coordination, safety compliance, and field execution from pre-construction through closeout.

System-Specific Engineering: Solutions matched to each facility’s conditions — 3-ply modified bitumen, coal tar pitch with rock ballast, standing seam metal, and PVC/TPO among them. Insulation upgrades and pitch corrections incorporated where applicable.
Production-Integrated Scheduling: Daily work windows coordinated with production managers to sequence roofing activity around operations below, whether that’s active casting, food processing lines, or live manufacturing.
Interior Protection: Temporary plastic installed inside as a secondary barrier against leaks, debris, or falling materials where roof age or operational sensitivity warrants it.
Permitting and Compliance: T&M manages specialized permitting for legacy system replacements and maintains fall protection systems at every penetration and leading edge on every site.

WHAT THIS DELIVERS

Zero production disruptions on active facilities
No incidents related to leaks, debris, or material intrusion
Energy performance improved through code-compliant insulation upgrades
Regulatory compliance achieved with all permits secured prior to mobilization
Mechanical clearances maintained after insulation additions
No safety incidents across any site
Extended asset life with reduced long-term maintenance exposure

THE RESULTS

Zero production disruptions on active facilities
No incidents related to leaks, debris, or material intrusion
Energy performance improved through code-compliant insulation upgrades
Regulatory compliance achieved with all permits secured prior to mobilization
Mechanical clearances maintained after insulation additions
No safety incidents across any site
Extended asset life with reduced long-term maintenance exposure

KEY TAKEAWAYS

When active production or sensitive operations sit directly below the work, execution planning carries the same weight as material selection. T&M’s experience across live industrial environments means the coordination, safety management, and permitting complexity of these projects is familiar ground. The result is work completed on schedule, within scope, and without creating new risk for the facility.

Have a project in mind? Give us a call at (971) 459-1805 or schedule a free consultation below.