Commercial Roof Inspection Checklist: 47-Point Field Protocol for Contractors & Adjusters

47-Point Commercial Roof Inspection Protocol

A systematic roof inspection identifies deficiencies before they become catastrophic failures. This checklist follows NRCA and ARMA guidelines and covers structural, membrane, flashing, drainage, and equipment conditions. Use it for bi-annual maintenance inspections, pre-storm preparation, and post-storm damage documentation.

Section 1: Structural & Deck Assessment (Points 1-8)

1. Deck deflection — walk the roof and note any soft spots, deflection, or ponding areas. Use a 6-foot level to measure sag exceeding L/240.
2. Structural fastener condition — spot-check mechanical fastener plates for back-out or corrosion (common on steel decks in humid climates).
3. Perimeter edge securement — verify metal edge flashing is mechanically attached at 12-inch on-center maximum per ANSI/SPRI ES-1.
4. Coping cap integrity — check for loose, dented, or displaced coping caps. Wind enters under loose coping and uplifts the membrane.
5. Expansion joint covers — inspect bellows for tears, compression set, or separation from curbs.
6. Deck-to-wall connections — probe for separation at roof-to-wall transitions, particularly at roof edges subject to wind uplift.
7. Roof-to-deck adhesion — for fully adhered systems, check for adhesive delamination by pushing on the membrane. Bubbles indicate bond loss.
8. Ponding water assessment — measure ponding depth. NRCA defines problematic ponding as water that remains 48 hours after rain. Ponding exceeding 1/2-inch depth over 25% of the roof area requires correction.

Section 2: Membrane Condition (Points 9-20)

9. Membrane surface — walk the entire field area. Note: blistering, ridging, splitting, cracking, or alligatoring patterns.
10. Seam integrity (TPO/PVC) — probe test at 18-inch intervals along heat-welded seams. Failed probe = cold weld = immediate repair needed.
11. Seam integrity (EPDM) — pull test adhesive/tape seams. Delamination greater than 2 inches requires seam overlay.
12. Membrane thickness — take core samples at 3 representative locations. Compare to manufacturer TDS specification. Thickness below 90% of nominal indicates wear requiring monitoring.
13. Puncture survey — document all existing punctures with location, size, and repair status. Unrepaired punctures are claim red flags.
14. Wear patterns — high-traffic areas around HVAC units, roof hatches, and access paths show accelerated wear. Verify walk pad coverage.
15. UV degradation — check for chalking, surface erosion, or reinforcement exposure on TPO/PVC. EPDM: check for ozone cracking at stress points.
16. Flashing condition — inspect base flashing at all walls, curbs, and equipment platforms. Counterflashing must overlap base flashing minimum 4 inches.
17. Penetration seals — check pipe boots, vent stacks, and conduit penetrations for cracking, pulling away, or weathered sealant.
18. Roof-to-wall transitions — verify step flashing or continuous flashing is intact with no gaps or lifted edges.
19. Condensation evidence — look for moisture staining on the membrane underside (if accessible) or blistering indicating trapped moisture.
20. Vegetation — remove any plant growth at membrane edges, seams, or penetrations. Roots penetrate seams and cause leaks.

Section 3: Drainage Systems (Points 21-30)

21. Gutters and downspouts — clear debris, check for sag, verify secure attachment.
22. Internal drains — verify dome strainers are clear and securely fastened. Check overflow drain outlets.
23. Scuppers — confirm unobstructed flow, verify cant strip and flashing condition at scupper openings.
24. Tapered insulation — verify roof slope directs water to drains (minimum 1/4-inch per foot per ARMA).
25. Sump pans — check condition of sump receiver pans at internal drains. Corroded pans leak at the deck connection.
26. Clamping rings — verify drain clamping rings are tight and sealed. Loose rings allow water intrusion at the drain body.
27. Overflow drains — confirm secondary overflow drains are clear and at correct height (2 inches above primary drain per IPC).
28. Conductor heads — verify conductor heads (leader boxes) are sealed and flash properly.
29. Gutter apron — check that gutter apron flashing extends into gutter minimum 1 inch.
30. Downspout discharge — verify downspouts discharge away from foundation. Improper discharge undermines footings and causes settlement claims.

Section 4: Rooftop Equipment & Accessories (Points 31-40)

31. HVAC unit curbs — verify curb flashing integrity, check for condensate overflow onto membrane.
32. Refrigerant lines — confirm line sets are supported and not resting on membrane.
33. Electrical conduit — verify conduit flashings and no membrane abrasion from vibration.
34. Roof hatches — check gasket condition, hinge operation, and curb flashing.
35. Skylights — inspect glazing for cracks, check curb flashing, verify condensation weep holes are clear.
36. Satellite/antenna mounts — verify proper flashing boots and no unauthorized penetrations.
37. Safety equipment — check guardrail, roof anchor, and fall protection tie-off condition per OSHA 29 CFR 1926.502.
38. Walk pads — verify coverage on all traffic paths. Missing pads accelerate membrane wear.
39. Roof signs and banners — confirm attachment method does not penetrate membrane. Surface-mounted only.
40. PV solar arrays — verify racking attachment method and flashing condition at penetration points.

Section 5: Documentation & Compliance (Points 41-47)

41. Photo documentation — photograph each deficiency with a scale reference and GPS-tagged location.
42. Moisture survey — perform infrared scan or nuclear gauge survey on suspect areas. Document moisture percentage.
43. Core samples — take minimum 3 core samples per roof section. Document thickness, attachment method, and deck type.
44. Manufacturer TDS cross-reference — verify installed materials match current manufacturer technical data sheets.
45. Warranty status — confirm active manufacturer warranty, document coverage terms and remaining duration.
46. Maintenance log — record all findings in a standardized log. Compare to previous inspection report.
47. Repair priority ranking — classify findings as: (A) immediate safety/emergency, (B) repair within 30 days, (C) monitor at next inspection, (D) planned maintenance.