Industrial Warehouse

Project Overview

When tasked with re-roofing a 1.1 million sq. ft. industrial warehouse, and replacing the existing EPDM Ballasted roof assembly, the 17,000 tons of ballast posed a waste problem. Partnering with Empire Roofing Corporation, a President’s Club Master Contractor, we saw an opportunity to turn waste into a resource. Instead of sending the removed EPDM ballast to a landfill, we worked together to repurpose it for road-base applications—giving old materials new life.

PROJECT IMAGES

THE CHALLENGES

Commercial re-roofing projects (when the old roofing system has reached the end of its service life and is replaced with a new system) often generate waste with materials like roofing ballast typically discarded after removal.

Therefore, the challenge on this project was clear: How could we minimize waste and maximize reuse and landfill diversion. The building’s large roof area made the task more demanding, with significant coordination needed to ensure the timely and efficient removal of the EPDM ballast.

RE-ROOFING SOLUTION

During the tear-off phase, the Elevate team was able to work with and leverage Lafarge Canada’s local gravel operations to repurpose the roofing ballast with the intent to reuse it for road-base applications. 17,000 tons of ballast was removed over two and a half months, averaging of 5-6 truck loads of roofing ballast each day!

Results:

1.1 million sq. ft. of EPDM ballast repurposed to support circular economy initiatives
Reduced demand for new raw materials for road-base applications, lowering environmental impact
Pioneered a scalable recycling model for future roofing projects

Ultraply TPO was chosen as the re-roofing membrane. TPO’s durability, energy efficiency, and heat-reflective properties made it an ideal choice for the building, addressing both the practical needs of the facility and the sustainability goals; a potential substrate for a solar array installation. Empire Roofing Corporation’s proficiency in installing Ultraply TPO systems also reduced installation time, minimizing disruption to the building’s operations.

To further enhance the roof's performance, the installation included ISOGARD GL Insulation, which delivers superior thermal performance and ensures energy efficiency. Together, these components created a reliable, energy-efficient roofing system ensuring long-term performance for the new roof.

Watch the Video

See the full journey of the EPDM ballast recycling project—from concept to completion. This video captures how innovative thinking, collaboration, and a commitment to sustainability came together to reduce waste and extend the life of valuable roofing materials!

Material Choices

Substrate Assembly

• Insulation: CGC Securock® Gypsum-Fiber Roof Board and EPS Insulation

• Fasteners and plates

Membrane and Attachment Membrane

• Membrane: UltraPly™ TPO

• Membrane Attachment: Mechanically Attached

• Warranty: 5 year

REFLECTIONS & PROUD MOMENTS

This project stands as a shining example of the innovative pathways we can create to reduce our waste footprint, paving the way for a cleaner, greener tomorrow. By reusing ballast, we're not just avoiding waste; we're conserving resources. This sustainable approach reduces the demand for new raw materials.

Will we engage in such projects again? Absolutely. The success in Ontario is just the beginning. Lafarge has an extensive network across of gravel sites across Canada that offer untapped potential for more waste diversion ventures.

The Elevate Canada team is all in when it comes to connecting the dots for a sustainable future, simplifying complex challenges, and delivering impactful solutions. As we reflect on this project, we invite you to join us on this journey of transformation—one roof, one idea, and one sustainable solution at a time.

For more information on our sustainability initiatives or waste diversion for your projects visit holcimelevate.com/ca-en/sustainability or contact your local Elevate sales representative.