Proactive roof maintenance is among the most important ways to protect your facility and avoid costly emergencies. One of the biggest Facility managers are often responsible for maintaining roofs they didn’t choose or planning upgrades to systems they don’t fully understand. Whether you’re preparing for a retrofit, evaluating overlay options, or budgeting for a future replacement, knowing the difference between a built-up roof and a single-ply system is essential.
This blog explains the key characteristics of both systems, including cost, durability, installation, and environmental performance, so you can make informed, confident decisions.
What Is a Built-Up Roof?
A built-up roof (BUR) is a multi-layer roofing system traditionally made with alternating layers of bitumen (asphalt or cold adhesive) and reinforcing fabrics. These layers are topped with a final layer of gravel, mineral cap sheet, or reflective coating.
BUR systems have been in use for over a century and are known for their redundancy and durability. They are commonly used on low-slope commercial roofs, especially in schools, government buildings, and industrial facilities.
What Is Single-Ply Roofing?
Single-ply roofing refers to membrane systems installed in a single layer, typically made from synthetic materials like TPO (Thermoplastic Polyolefin), PVC (Polyvinyl Chloride), or EPDM (Ethylene Propylene Diene Monomer).
Unlike BUR systems, which rely on multiple layers for protection, single-ply systems provide a lightweight, flexible solution that uses chemical and mechanical bonding for waterproofing and UV resistance.
Installation Differences Between Built-Up Roof and Single-Ply Roofing
Installation processes vary greatly between BUR and single-ply systems. Each method impacts project timing, labor needs, and potential disruption to building occupants.
BUR installation is typically more time-consuming. It involves heating asphalt or applying cold adhesives, layering reinforcing felts, and then adding ballast or coating. This method is labor-intensive and can produce strong odors, which may affect occupied buildings.
In contrast, single-ply systems are quicker and cleaner to install. Membranes are laid in large sheets and secured with mechanical fasteners, adhesives, or ballast. Because there are fewer layers and less equipment required, projects often finish faster.
If minimizing disruption is a priority, single-ply installation is often the better choice.
Cost Considerations: Which System Is More Budget-Friendly?
Initial costs depend on roof size, condition, and material selection. However, single-ply systems are generally more affordable up front.
BUR systems require more materials and labor, increasing overall costs. Despite this, their durability and long lifespan can make them a cost-effective choice over time if properly maintained.
Single-ply systems are easier and less expensive to install, but may need more frequent inspections or repairs in high-exposure areas. Evaluating long-term maintenance and lifecycle expenses is key when comparing the two.
Durability and Maintenance: How Do They Hold Up?
Both systems perform well with proper care, but their strengths differ based on usage and climate.
BUR is known for its strength and redundancy. Multiple layers help resist punctures and reduce the risk of water infiltration. However, gravel surfacing can hide damage, making maintenance more challenging and leaks harder to detect.
Due to their smooth surfaces, single-ply membranes are easier to inspect and repair. While they may be more vulnerable to punctures or seam issues, routine maintenance can prevent these from becoming serious problems.
Proactive commercial roof maintenance is essential for either system to perform reliably over time.
Environmental and Energy Performance
Facility managers often consider sustainability and energy efficiency when choosing a roofing system.
BUR systems can be modified with reflective coatings to meet cool roof standards, but they tend to retain heat and are heavier, which might not be suitable for every structure. Some BUR products may also contain higher levels of VOCs, which can complicate installation.
Single-ply systems like TPO and PVC offer high reflectivity, which reduces cooling loads and supports energy efficiency goals. Their lightweight nature makes them suitable for older or structurally limited buildings.
If reducing energy costs and environmental impact is important, single-ply systems generally offer greater advantages.
Warranty Options and Longevity Expectations
Warranty terms vary by manufacturer, but both systems can offer strong protection with proper installation and upkeep.
BUR systems typically offer long-term durability and may qualify for extended warranties if regular inspections are documented.
Single-ply membranes also come with competitive warranties, particularly for reinforced versions of TPO and PVC. Their simpler structure often makes it easier to maintain warranty compliance.
Always review the terms of each warranty, including what maintenance is required to keep coverage in place.
Where Each Roofing System Excels (and Falls Short)
Choosing between a built-up roof and a single-ply system often depends on your building’s unique needs.
Built-Up Roofs: When They Work Best
Built-up roofing is a proven system, particularly in environments that demand durability and resilience. These systems perform well in regions with large temperature swings. Their multi-layer construction helps buffer the building from heat and cold. If your facility has heavy rooftop equipment or experiences regular foot traffic from maintenance crews, the layered protection of a built-up roof offers added strength. BUR is a smart investment for long-term performance, especially for institutional or industrial facilities.
When Built-Up Roofs May Not Be Ideal
Despite their strengths, built-up roofs have limitations. Installation can be noisy, odorous, and disruptive, especially in occupied buildings. Their weight may exceed the load capacity of older structures. Because BUR systems require more time and labor to install, they are not ideal for projects with tight schedules or limited access.
Single-Ply Roofing: Ideal Use Cases
Single-ply roofing systems are especially effective on large commercial roofs where speed, simplicity, and energy efficiency matter. Their lightweight design and reflective surfaces make them a strong choice for buildings focused on sustainability. Installation is typically faster and less invasive. They are well-suited for warehouses, retail centers, or commercial buildings that prioritize cost control and scheduling.
When Single-Ply Roofing Might Fall Short
While efficient and easy to install, single-ply systems may not be ideal for every facility. Roofs with frequent foot traffic, especially near rooftop equipment, or those prone to debris, can increase puncture risks. In remote buildings where maintenance access is limited or in climates with extreme weather, single-ply roofs may require more frequent inspections.
Industry Trends and the Shift Toward Single-Ply
Many facility managers prefer single-ply systems for new construction and retrofits. Their lower installation cost, cleaner application process, and strong energy performance make them attractive for many commercial buildings.
However, BUR systems remain relevant for certain buildings, especially where redundancy and long-term resilience are valued. Government and institutional facilities often continue to rely on BUR for their reliability.
Understanding these industry shifts can help inform your long-term planning and project decisions.
Switch to single-ply roofing with Kodiak Roofing & Waterproofing. Our commercial single-ply roofing can enhance your building and increase your investment.
Making the Right Choice for Your Facility
The best roofing system is the one that fits your facility’s structural needs, budget, and performance goals. Whether you’re overseeing a school, warehouse, or multi-use property, understanding the core differences between a built-up roof and single-ply membrane systems allows you to make better-informed decisions.
Evaluate your climate, access needs, and long-term plans. Don’t make a decision based solely on price or convenience.
Work with a contractor who has deep experience with both types of systems to find the best fit.
Choose the Right Material for Your Roof With Kodiak Roofing & Waterproofing
At Kodiak Roofing & Waterproofing, we’ve installed, repaired, and maintained thousands of roofing systems, including BUR and single-ply. We don’t believe in one-size-fits-all solutions. We help you evaluate your situation, compare options, and choose the best system for your building’s future.
Contact us today to assess your current roof, discuss reroofing possibilities, and plan the right solution—whether a built-up roof or single-ply system.
