Built-Up Roofing (BUR) Guide for DFW Commercial Buildings

What Built-Up Roofing Actually Is

BUR is exactly what it sounds like: multiple layers of bitumen (asphalt) and reinforcing felt or fiberglass ply sheets, built up in place. A standard 4-ply BUR system uses alternating layers of hot bitumen and ply sheets — four layers total — with a surface treatment of gravel, a mineral cap sheet, or a reflective coating. The gravel surface, which you see on older commercial buildings across Dallas, Irving, and Fort Worth, embeds into the top bitumen layer and serves as both UV protection and ballast. It's not decorative — it's functional. The gravel literally shields the bitumen from solar degradation that would otherwise crack and dry out the membrane in 8-10 years.

BUR vs TPO vs EPDM: The Real Comparison

On new commercial construction in DFW today, TPO wins most of the time on cost and installation speed. TPO installs faster (no hot kettle, no gravel), comes with cleaner reflective surfaces for energy efficiency, and requires manufacturer-certified contractors who can issue NDL warranties. EPDM is the choice when chemical resistance matters or when you need a membrane that performs reliably in extreme temperature swings. BUR holds its ground in specific situations: existing BUR buildings where a partial repair is more economical than full replacement, buildings with heavy rooftop foot traffic where the gravel surface provides traction and durability, and owners who value multi-ply redundancy over single-membrane systems. Cost comparison on new installation in DFW: BUR runs $6-$10/sqft installed; TPO runs $5-$9/sqft; EPDM runs $5-$8/sqft. BUR is no longer cheaper than single-ply — labor intensity has changed that math.

Repairing vs Replacing Existing BUR

If you have an existing BUR roof, the repair question comes down to wet insulation percentage and flashing condition. Less than 10% wet insulation with good flashings: repair and maintain. Ten to 25% wet insulation: major repair with targeted tear-out of wet sections and re-membrane over those areas. Over 25% wet: full tear-off and replacement, because the substrate is compromised. The thermal scan is how we determine which bucket you're in. BUR repairs themselves are straightforward — cut out the damaged area, dry it, re-apply plies and bitumen, re-gravel. The work is messier than single-ply membrane repairs, but the technique is reliable and has been refined over a century.

When BUR Makes Sense in 2026

For new commercial construction in DFW, BUR is rarely the first recommendation — TPO's cost, speed, and energy performance have shifted the market. But for existing BUR buildings in serviceable condition, replacement with a new BUR system makes sense when the substrate is good, the owner wants to maintain the existing system type, and the building doesn't require the energy performance of a white reflective TPO. We do BUR work on existing systems across North Texas — from warehouse districts in Grand Prairie to industrial parks along I-35. Call JRH at (469) 888-6903 if you have an existing BUR roof and want an honest assessment of what it needs.