Built Up Roofing Manufacturers and BUR Systems: A Comprehensive Guide

Built up roofing, commonly known as BUR, is a durable, multi-layer membrane used on commercial and industrial flat roofs. This article explores the landscape of built up roofing manufacturers, the materials and processes behind BUR systems, and practical guidance for selecting a reliable manufacturer. It covers key membranes, performance characteristics, code considerations, and sustainability trends shaping the market for built up roofing in the United States.

What Is Built Up Roofing (BUR)?

Built up roofing is a multi-ply membrane constructed from alternating layers of bitumen and reinforcing sheets, topped with a protective cap layer. The classic BUR assembly uses asphalt or coal tar pitch as the waterproofing medium, with fabric reinforcement between plies. Modern BUR systems often incorporate polymer-modified bitumens for enhanced elasticity and weather resistance. The final surface may be coated with gravel or a mineral granule finish, which provides UV protection and ballast. Key advantages include long service life, proven waterproofing, and versatility for various roof types and climates.

Key Materials Used In BUR

Materials influence performance, maintenance, and longevity. Common components include:

• Bitumen Types: Asphalt-based or coal tar pitch, with polymer modification improving flexibility and aging resistance.
• Reinforcement: Tensile fabrics such as polyester or fiberglass plies that stabilize the membrane.
• Pavings Or Cap Sheets: Gravel, mineral granules, or reflective coatings to protect the surface.
• Cold-Applied Or Hot-Asphalt Apps: Application methods vary by climate, building codes, and contractor preference.
• Waterproofing Additives: Fiberglass sheets and sealants for edge detailing and penetrations.

Manufacturers in the BUR space typically offer complete systems, including primers, base sheets, ply sheets, cap sheets, and surface finishes. The choice of materials affects fire ratings, UV resistance, and thermal performance, influencing building energy codes and insurance requirements.

Leading Built Up Roofing Manufacturers In The United States

Several manufacturers dominate the BUR market with comprehensive product lines, technical support, and warranty programs. Notable players include:

• Warner Roofing And Built-Up: Known for durable asphalt and coal tar BUR products, with extensive contractor networks.
• IKO Industries: Offers BUR systems alongside modified bitumen membranes and single-pply options, backed by global distribution.
• GAF Materials Corporation: A leading roofing brand providing BUR cap sheets, base plies, and moisture barriers integrated with their overall roof systems.
• Beacon Roofing Supply (Private-Label Partners): Distributes BUR components from multiple manufacturers, supporting project-specific needs.
• Firestone Building Products: Provides polymer-modified BUR systems with enhanced fire resistance and durability.
• Tremco Commercial Sealants & Waterproofing: Focuses on high-performance BUR membranes for demanding environments.

Regional manufacturers and regional distributors also play a critical role, delivering localized technical support, installation training, and product availability for retrofit projects or climate-specific requirements.

Manufacturing Process And Quality Standards

A typical BUR manufacturing and application workflow includes product formulation, ply preparation, and field installation. Manufacturers emphasize the following:

• Quality Control: RoHS-compliant components, consistent ply thickness, and uniform bitumen application to minimize delamination risks.
• Fire Resistance: When required, certain BUR assemblies meet Class A fire ratings, achieved through mineral granule toppings and specific bitumen formulations.
• Environmental Practices: Recycled content in cap sheets, solvent-free primers, and low-VOC finishes align with green building standards.
• Application Methods: Hot-applied asphalt or cold-applied bitumen; temperature control is critical for performance in different climates.
• Quality Assurance: Field tests for adhesion, permeability, and lap integrity, plus manufacturer warranties based on inspection protocols.

Manufacturers provide detailed installation guides and BOMA/ASHRAE-aligned performance data to help specifiers evaluate long-term reliability and lifecycle costs.

Applications, Standards And Inspection

BUR is favored for flat or low-slope commercial roofs, parking structures, and retrofit projects where a robust waterproof system is needed. Important considerations include:

• Climate Adaptation: BUR performance varies with wind uplift, temperature, and UV exposure; reflective cap sheets help moderate cooling loads in hot climates.
• Aging And Maintenance: BUR requires periodic inspection for surface damage, granule loss, and edge leaks. Timely resealing extends service life.
• Codes And Certifications: Compliance with ASTM standards, AAMA, and local building codes is common. Fire resistance ratings and wind uplift tests influence product selection.
• Inspection Protocols: Roofing consultants and inspectors assess ply integrity, seam adhesion, drainage, and membrane puncture resistance.
• Warranty Considerations: Manufacturer warranties typically cover material defects, with workmanship warranties provided by contractors and installers.

Customers benefit from a clear specification package that includes performance data, installation instructions, and maintenance guidelines tailored to the building’s use and locale.

Choosing The Right BUR Manufacturer

Selecting a BUR manufacturer involves evaluating product performance, support, and total cost of ownership. Key steps include:

• Technical Compatibility: Ensure the system aligns with existing roof decks, insulation, and edge details.
• Warranty And Support: Review coverage for materials and workmanship, response times, and availability of local technical support.
• Proven Performance: Request case studies in similar climates and building types, plus third-party test results.
• Supply Reliability: Assess regional distribution, lead times, and contingency plans for material shortages.
• Life-Cycle Cost: Consider energy savings from reflective cap sheets, maintenance frequency, and expected replacement cycles.

Specifiers should collaborate with roofing contractors to verify compatibility with the chosen BUR system and to schedule installation during optimal weather windows for performance and safety.

Sustainability And Codes Impacting BUR

Sustainability trends shape BUR choices, driving demand for lower-emission materials and recycled content. Manufacturers are responding with:

• Low-VOC Primers and Adhesives: Reducing indoor air quality concerns during and after installation.
• Recycled Content Cap Sheets: Incorporating reclaimed materials to lower environmental impact.
• Energy-Efficient Surfaces: Reflective granules and white coatings reduce cooling loads and urban heat island effects.
• Durability And Lifespan: Longer service life reduces waste and replacement frequency, aligning with circular economy goals.
• Code Alignment: BUR systems increasingly meet Energy Star standards and fire-safety requirements mandated by local authorities.

Understanding these factors helps owners and developers select BUR solutions that balance performance, compliance, and sustainability goals.

Practical Takeaways For Projects

To maximize value from built up roofing, consider:

• System Compatibility: Align BUR components with existing insulation and deck types for optimal adhesion and thermal performance.
• Climate-Specific Design: Select bitumen and cap sheet formulations tested for local wind, temperature, and precipitation patterns.
• Inspection Regularity: Establish a maintenance schedule with clear inspection criteria and documentation.
• Manufacturer Support: Favor manufacturers with robust technical service, training programs, and readily available replacement parts.
• Life-Cycle Considerations: Weigh upfront costs against long-term energy savings, reduced maintenance, and warranty protections.

By integrating these considerations, project teams can achieve durable waterproofing, predictable maintenance costs, and a resilient roof system that stands the test of time.