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Foot Levelers | Roanoke, VA
A new 60 mil TPO roof system installed directly over the existing metal panel roof at Foot Levelers’ Roanoke manufacturing facility, with no tear-off required.
Service
Industry
System
Location
TPO Roof Retrofit Over Metal | Manufacturing Facility
Foot Levelers’ Roanoke facility had an existing metal panel roof, and rather than removing it, our Roanoke crew built a new TPO system right on top. We first filled the flutes, the low channels between the metal panel ribs, with EPS foam insulation to create a level surface. Over that, we installed a 1″ polyiso cover board and a 60 mil TPO membrane. The membrane was secured with Rhinobond, an induction-welded attachment method that bonds the TPO to plates beneath it, so the membrane itself is never pierced by fasteners. The project was completed in March 2025.
Building over the existing metal avoided the cost and disruption of a full tear-off. The flute fill and cover board give the new membrane a solid, even base, and the Rhinobond attachment leaves a continuous TPO surface with fewer potential leak points. Every step was handled by our own crews rather than subcontractors, and as a 100% employee-owned company, we stand behind this roof for the long haul.