When replacement beats another repair
Replace the roof when the damage is no longer isolated: active leaks in several areas, wet insulation across the deck, seams failing throughout the field, or a membrane at the end of its service life. The rule of thumb is 25–30% — once that much of the roof is compromised, replacement costs less per remaining year than chasing leaks. If your roof is not there yet, start with commercial roof repair or a restoration coating.
How much does a commercial roof replacement cost?
Budget $9 to $20 per square foot for a full tear-off and new system installed. Where the existing roof is dry and code allows it, a recover costs less and is quoted per roof. Bigger roofs price nearer the bottom of the range, small and complicated ones nearer the top.
| Roof size | Tear-off and new system |
|---|---|
| 5,000 sq ft | $45,000 – $100,000 |
| 10,000 sq ft | $90,000 – $200,000 |
| 25,000 sq ft | $225,000 – $500,000 |
| 50,000 sq ft | $450,000 – $1,000,000 |
What moves the number
- Tear-off vs. recover. Removing the old roof costs real money in labor and disposal. A recover, where code allows it and the insulation is dry, is the cheaper path and is quoted per roof.
- Insulation. Code-required R-value and any tapered insulation to fix ponding are often the single biggest line item after the membrane.
- Deck condition. Rusted steel or rotted wood decking found at tear-off is repaired before the new system goes on. We core-cut first so this is priced, not a surprise.
- Details and penetrations. A roof crowded with HVAC curbs, skylights and pipes costs more per foot than an open field.
- Warranty length. A 20-year NDL manufacturer warranty requires a thicker membrane and heavier attachment than a 10-year material warranty.
- Access. Crane time, night work, or staging in a live parking lot all add cost.
Which system for your building?
| System | Relative cost | Service life | Best for |
|---|---|---|---|
| TPO | Middle | 20 – 30 yrs | Most low-slope roofs; reflective, lowers cooling load |
| EPDM | Lower | 20 – 30 yrs | Large simple roofs, cold climates, tight budgets |
| PVC | Higher | 25 – 35 yrs | Restaurants and plants with grease or chemical exhaust |
| Modified bitumen / BUR | Middle | 20 – 30 yrs | High-traffic roofs, redundancy in multiple plies |
| Standing seam metal | Highest | 40 – 70 yrs | Sloped roofs, longest life, hail-rated options |
| Spray foam (SPF) | Lower | 25 – 35 yrs | Irregular roofs, added insulation without tear-off |
What the project looks like
- Inspection and core cuts. We measure the roof, cut cores to see every layer and check how wet the insulation is, and note the deck type, drainage and code requirements.
- Written proposal. System options side by side, line-item pricing, warranty terms and a schedule — not a one-page total.
- Pre-construction plan. Staging, dumpster placement, tenant notice, parking, safety, and how we keep the building dry each night.
- Tear-off or recover. Only as much roof comes off in a day as we can dry in that day.
- Install to manufacturer spec. Insulation, attachment pattern, membrane, then flashings and edge metal — the details that decide whether a roof leaks in year three.
- Manufacturer inspection and close-out. The manufacturer signs off for the warranty; you get photos, the warranty paperwork and a maintenance schedule.
Paying for it
Three routes, often combined: an insurance claim when the failure came from hail or wind (see roof insurance claims), financing that spreads the cost over the life of the roof, and phasing — replacing the worst section this year and budgeting the rest for next. We will tell you which sections can wait and which cannot.
Replacement projects
Frequently asked questions
How long does a commercial roof replacement take?
Roughly a week per 10,000 square feet in good weather, longer for tear-offs, heavy insulation work or roofs crowded with equipment. Your proposal gives a dated schedule, and the building stays watertight every night.
Do we have to close while the roof is replaced?
No. Offices, retail and warehouses stay open through almost every replacement. We plan staging and noise around your hours, and coordinate any work over occupied space in advance.
Can we put a new roof over the old one?
Sometimes. Code generally allows one recover over a single existing layer, provided the insulation underneath is dry and the deck is sound. A recover saves 15–25%. If the core cuts come back wet, a recover just traps the water, and we will say so.
What warranty comes with a new roof?
Two separate warranties: the manufacturer’s on the system, typically 10 to 30 years depending on membrane thickness and assembly, and ACR’s workmanship warranty on the installation. Both are in writing in your proposal, before you sign.
Will a new roof lower our energy bills?
Usually, yes. A reflective white membrane plus code-current insulation cuts summer cooling load noticeably in Kansas City and Atlanta. Over 25 years, a reflective TPO roof is among the lowest total-cost systems once energy is counted.
Commercial roof replacement in: Kansas City · Topeka & NE Kansas · Metro Atlanta