Core Cuts — A Key to Understanding Your Commercial Roof System
Measuring the depth of a commercial roofing system via core cut
Commercial roofing systems are complex assemblies, necessitating an in-depth understanding to maintain their integrity and longevity. Core cuts are an essential diagnostic method for commercial roofers to perform detailed analysis on each layer of the roof — especially those not visible on the surface. This procedure is vital in detecting potential issues early and determining the true condition of your roof.
What are Roofing Core Cuts?
A core cut, or a roof core analysis, is a crucial diagnostic method employed in the field of commercial roofing. Far from being a simple, singular layer, commercial roofing systems are intricate multi-layered structures, designed with the specific purpose of protecting the building from environmental elements while providing insulation and managing moisture. As such, understanding these layers and their condition is critical to maintaining the roof's integrity and longevity.
The core cut process involves cutting and extracting a small sample from all the layers of the roof—right from the surface membrane through the insulation and down to the roof deck. Much like a biopsy in medical procedures, this sample provides a comprehensive view of the roof's existing conditions, offering invaluable information about each layer of the roofing system.
The core cut gives a clear picture of the roof’s overall condition, revealing issues that aren’t visible from a surface inspection. By identifying problems in their earliest stages, minor issues can be prevented from escalating into major, costlier repairs. The core cut allows us to make informed decisions regarding necessary repairs or even a complete roof replacement.
The Process of Core Cutting - Step By Step
The first step in the process of taking a core sample is selecting the area in which a core cut should be taken from — core cuts are typically taken in pairs, with one cut on the high side of the roof and a second cut on the low side of the roof.
Using a coring tool, cut into the roofing system. Before cutting into the roofing system, its imperative to identify the decking style that is underneath the system — different deck styles require different cutting techniques, and using improper techniques can lead to costly damages. With a metal deck, it will be obvious when you have cut through the roofing system, but on gypsum, tectum, and wood decks, much more care must be taken to avoid puncturing the deck. Repeat this process in the other site picked for a core sample.
Once the two core samples have been taken, the samples must be examined. A difference in depth at the two cut sites generally suggests that the insulation is responsible for the slope of the roofing system; if the cuts are the same depth, the structure of the building is responsible for providing the slope for the roofing system. The core samples should also give information about the decking material and condition, the insulation type, the membrane used, the moisture content, and the presence of a vapor barrier — this information will be used to formulate the best plan for your roofing system, whether that’s repair, replacement, or no action.
Restore the material to the site of the core cuts. At this point, the cut itself must be patched to prevent leaking in the future. To do this, the material removed from the roof should be reinserted into the cut made in step 1. Once the materials and insulation have been returned to their location, the membrane itself must be patched. The process of patching the membrane is different for each membrane: for TPO and PVC membranes, a heat welded patch is applied; for modified bitumen roofing systems, a layer of roofing cement is applied, then a patch, then another layer of roofing cement; for EPDM, the area is cleaned, primer is applied, and a patch is applied that bonds with the primed area.
Interpreting Core Cut Results
After extracting a core sample, we carefully analyze each layer, applying our decades of commercial roofing expertise to identify problems and formulate solutions. Core cuts can reveal problems at any layer of the roof, from the membrane to the insulation, and the results need to be interpreted by an expert to evaluate the best course of action for your roof.
Core cuts often reveal invisible problems, such as water, in a roofing system. Water can infiltrate the roof system via leaks, leading to trapped moisture within the insulation or even the roof deck. This dampness can cause rot, mold growth, and structural degradation over time. In such instances, repairs or replacement of the affected area is often required to prevent further deterioration.
The core cut can also provide vital insights about the insulation and underlying structure. Deteriorated or compressed insulation will not perform its function optimally, leading to inefficient energy use and potentially higher utility bills. Different types of insulation degrade in unique ways, and our expertise can identify these signs accurately. Depending on the extent of the degradation, we may recommend replacing the insulation layer or in some cases, the entire roofing system.
Another scenario that could be unveiled through a core cut is the presence of multiple roof layers. While it's not uncommon for a new roof to be installed over an old one, too many layers can become problematic, adding excessive weight and making it more difficult to locate and repair future leaks. Building codes limit the number of permissible layers, and a core cut is a surefire way to reveal if a roof is in violation.
Finally, a core cut allows us to examine the condition of the roof deck. Issues like rust (in metal decks), rot (in wood decks), or cracks (in concrete decks) can all be detected through this analysis, dictating whether deck repair or replacement should be included in the roofing project.
Interpreting these core cut results helps us to create a clear plan for maintenance, repair, or replacement. It enables us to identify potential issues early, target our efforts more precisely, and provide you with the most cost-effective, long-lasting solutions for your commercial roof. At the end of the day, the core cut gives us, and you, the peace of mind that comes from knowing the true condition of your roof.