TPO · Distribution Center
200,000 SF Distribution Center — Complete TPO Replacement
Grand Prairie, TX
200,000 SF Distribution Center — Complete TPO Replacement
After200,000 SF Distribution Center — Complete TPO Replacement
BeforeDrag the slider to compare before and after — Aged BUR (25+ years) replaced with TPO
Project Details
Property Type
Distribution Center
System Installed
TPO
Previous System
Aged BUR (25+ years)
Square Footage
200,000 SF
Duration
18 days
Completed
November 2025
Location
Grand Prairie, TX
The Challenge
A 200,000 square foot distribution center with an aging BUR roof system experiencing multiple leak points, saturated insulation across 30% of the roof area, and increasing energy costs. The facility operates 24/7 with high-value inventory — zero tolerance for water intrusion during the replacement process.
Our Solution
MAZE executed a phased TPO replacement across four zones, maintaining full building operations throughout. Each zone included complete tear-off, insulation replacement, and 60-mil TPO membrane installation with heat-welded seams. Infrared scans verified zero moisture under the new system before each zone was closed out.
The Result
Full 20-year manufacturer warranty activated. Energy costs reduced by an estimated 22% in the first quarter. Zero inventory damage during the 18-day phased installation. The facility manager reported no operational disruption to their 24/7 shipping schedule.
What the Client Said
“We were running shipments the entire time MAZE was on the roof. They phased the work so precisely that our operations never missed a beat. And the energy savings have already exceeded what they projected.”
Operations Director
Facility Management, National Distribution Company
Additional photos coming soon
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