Built-Up Roofing (BUR) Systems in PA, NJ, DE, & MD

Commercial Built-Up Roofing (BUR)

When Fred Gooding started his roofing business in 1946, there was only one choice for commercial low-slope roofs: the built-up roofing (BUR) system. Today, BURs can be cold-applied or hot-mopped, finished with a smooth coating or gravel surface, and made with either modified or traditional bitumen.

Our experts are ready to partner with you to install this durable and time-tested roofing system.

What Is Built-Up Roofing (BUR)?

Built-up commercial roofing in Eastern PA, NJ, DE, & MD

Once called asphalt roofs, the construction of built-up roofs involves a layering process using bitumen (made from asphalt, coal tar, or cold adhesive) and reinforced fabric. Roofers have used these versatile membrane systems for decades on low-slope and flat roofs.

The first applied layer is the bitumen. It’s then topped with fabric, felt, or fiberglass from a roll. These layers are repeated based on the project. The completed roof often has a surface aggregate (for aesthetics and longevity) and an optional reflective coating (for energy savings).

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Why Built-Up Roofing Remains a Reliable Choice for Commercial Buildings

The best feature of a built-up roofing system is redundancy. This roof type is “built up” with several layers — each one offering protection if the layer above it becomes damaged. Although these roof membranes aren’t as popular today as they once were, they still provide a viable option for new construction and roof replacements.

As we mentioned earlier, this system for flat roofs was more popular in the 1970s, but it’s still around today because it’s rugged, dependable, and long-lasting. This commercial roof is water-resistant, protectant against UV rays, fire-resistant, resilient against wind and rain, and low-maintenance (requiring only one to two annual inspections).

Ideal Applications

A commercial built-up roof might be the best option if your operation cannot tolerate a roof leak. That includes:

Food manufacturers
Museums
Hospitals and healthcare facilities
Buildings containing high-value items

BUR also excels in commercial, industrial, and institutional settings where durability and long-term performance are paramount. It’s particularly well-suited for high-traffic roofs, buildings in harsh climates, and large facilities.

Get in touch with GSM Roofing today, so we can talk about a built-up roof, and its cost, longevity, maintenance, installation, repairs, and more!

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Built-up roof systems for commercial flat roofs

Let’s See if Built-Up Roofing is the Right Choice for Your Commercial Building

Built-up roofing for commercial low-slope roof

If you’re looking for a proven, low-maintenance option for your commercial low-slope roof, you might want to consider built-up roofing. Our commercial roofing experts are ready to discuss the advantages and disadvantages of this type of roofing, your needs and expectations, and other options that may work even better than a built-up roof system.

Not only will we install or repair your roof the right way, but we will also use our eight decades of experience with roofing membranes to prescribe the best, most economical solutions for your commercial structure. We proudly serve businesses throughout Pennsylvania, New Jersey, Maryland, and Delaware.

Reach out to our roofing specialists today!

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What are the Main Benefits of a Built-Up Roof?

Exceptional durability: The multi-ply design creates built-in redundancy; a puncture, cut, or abrasion on the top layer is highly unlikely to penetrate all subsequent layers of bitumen and felt.
Superior waterproofing: When hot asphalt is mopped between plies, it creates a monolithic, seamless membrane across the entire roof field. This continuous surface eliminates the need for joints or seams in the main roofing area, which are the most common points of failure in many other commercial roofing systems.
High puncture and impact resistance: The aggregate or mineral surfacing acts as a durable armor for the roof membrane. It provides excellent protection against damage from hail, falling branches, dropped tools, and other impacts that could easily puncture a less robust system.
Excellent for high foot traffic: The combination of the multi-ply membrane and the hard surfacing makes BUR exceptionally resistant to the wear and tear of regular maintenance traffic. This is a critical advantage for commercial buildings with significant rooftop mechanical or solar equipment.
Class A fire resistance: The gravel or mineral aggregate surfacing is non-combustible, giving BUR systems a high degree of fire resistance. This is a crucial safety feature that can help lower insurance premiums and provide peace of mind.
Proven UV protection: The surfacing layer effectively blocks harmful ultraviolet radiation from reaching the underlying waterproofing bitumen. This protection prevents the asphalt from drying out, cracking, and degrading prematurely, which is a primary factor in the system’s long service life.

What are the Known Disadvantages or Challenges with BUR Systems?

Heavy weight: BUR systems are substantially heavier than their single-ply counterparts. This added dead load may require a structural analysis by an engineer to confirm that the building’s frame and deck can safely support the weight, potentially adding cost and complexity to the project.
Complex and labor-intensive installation: The process of building up multiple layers is slow, physically demanding, and requires a high level of skill and attention to detail from the roofing crew.
Odors and fumes during installation: The traditional hot-applied method involves heating asphalt in a kettle, which releases strong, pungent fumes. These odors can be disruptive to building occupants and may require special ventilation considerations or scheduling the work during off-hours, particularly for sensitive facilities, like hospitals or schools.
Difficult leak detection: When leaks occur, they can be harder to locate because water may travel between multiple layers before becoming visible. This can make troubleshooting and repairs more complex and time-consuming. However, GSM offers infrared roof inspections that can help locate the trapped moisture.
Susceptibility to ponding water: Like all low-slope roofing systems, BUR is vulnerable to the effects of ponding water — water that remains on the roof surface for more than 48 hours.

How Much does a Built-Up Roofing System Cost?

BUR systems typically have a higher upfront cost than single-ply options. However, their long lifespan and low maintenance needs often make them more economical over time.

BUR costs vary based on:

Number of layers (plies): more ply layers = more material and labor
Surface finish: gravel, smooth coating, reflective surfacing, etc. add cost
Accessibility: how easy is the commercial roof to reach, work on, etc.
Roof size and shape: bigger, simpler roofs usually cost less per square foot; complicated geometry or penetrations increases cost
Removal vs. overlay: tear-offs increase cost
Local code: Energy or fire codes can affect cost

How Long does a Commercial Built-Up Roof Last?

A professionally installed BUR system has an average expected service life of 20 to 30 years. Its longevity depends on factors, such as the number of plies, climate, proper drainage, and how well the roof is installed and maintained.

What Maintenance does this System Require?

Commercial BUR roofs are low-maintenance but should be inspected at least once or twice a year for signs of cracking, blistering, or ponding water. The roof surface, drains, scuppers, and gutters should be cleared of leaves, branches, and other debris to help prevent clogged drains.

Routine roof maintenance can extend the lifespan and prevent costly repairs.