PROJECT SNAPSHOT | Carlisle TPO flat roof
| Client | Anthony C. — Eagle St, Midtown Houston, TX 77004 |
| Property | Residential — flat roof, multi-story structure |
| Scope | Full flat roof tear-off and replacement — Phase 1 of 2 |
| Material | 115MM fully adhered (glue-down) Carlisle TPO membrane |
| Insulation | Polyisocyanurate (ISO) insulation board |
| Special scope | Siding removal/reinstall, scupper reflashing, wall termination waterproofing |
| Workmanship warranty | 5 years — upgraded from standard 1-year (client-negotiated) |
| Veteran discount | A discount applied — Achilles Roofing honors disabled veterans |
| Installation date | June 20, 2026 |
| Invoice date | June 23, 2026 |
| Paid in full | June 23, 2026 |
| Investment | Contact for a free estimate |
| Project lead | Ahmad Faiz |
| Phase 2 (upcoming) | Ground Smart Smart Loc rubber paver walkway system — in progress |
The Situation: A Flat Roof Past Its Service Life
Anthony home on Eagle Street in Midtown Houston had a flat roofing system that had reached the end of its service life. Houston’s combination of intense summer heat, UV exposure, seasonal storms, and high humidity accelerates the degradation of flat roofing membranes — and the existing system was no longer providing reliable waterproofing protection.
Before contacting Achilles Roofing & Exterior, Anthony did his homework. He asked detailed questions about TPO membrane thickness (60mil vs 80mil vs 115mil), manufacturer options, and warranty coverage — the kind of informed questions that push a roofing contractor to bring their best recommendation to the table.
Ahmad Faiz responded with full transparency: confirmed the Carlisle roofing system, offered a 60mil-to-80mil upgrade option at $950, and ultimately delivered a 115mil fully adhered system with a 5-year workmanship warranty — well above the standard 1-year warranty — as the right solution for Anthony’s property.
Why Carlisle 115MM Fully Adhered TPO Was the Right Choice
Not all TPO membranes are equal. The choice of manufacturer, thickness, and installation method each play a significant role in the long-term performance of a flat roof in Houston’s climate.
Carlisle roofing systems — commercial-grade performance for residential roofs
Carlisle SynTec is one of the most widely respected names in commercial and residential flat roofing. Their TPO systems are engineered to perform in demanding environments — UV stability, heat weldability, and dimensional stability under thermal cycling. Using a Carlisle system ensures that every component of the roofing assembly — membrane, insulation, accessories — is designed to work together, and that manufacturer warranty documentation can be provided upon completion.
115MM membrane — the thickest standard TPO available
Standard residential TPO installations use 45mil to 80mil membranes. At 115mil, the fully adhered membrane installed at Eagle Street is the heaviest-duty option in the standard TPO range — providing substantially greater puncture resistance, dimensional stability under Houston’s extreme temperature swings, and a longer service life before replacement is needed. For a homeowner who asked specifically about membrane thickness before signing, this was the right answer.
Fully adhered (glue-down) installation — maximum wind uplift resistance
The Carlisle system at Eagle Street was installed fully adhered — meaning the membrane was glued directly to the ISO insulation board across the entire surface, rather than mechanically fastened at discrete attachment points. A fully adhered system creates a continuous bond that resists wind uplift more effectively than mechanically fastened alternatives, with no discrete fastener locations that could become water entry points over time. In a city that faces tropical storm-force winds every hurricane season, this installation method is the more conservative, higher-performing choice.
5-year workmanship warranty — earned, not given
Achilles Roofing’s standard workmanship warranty is one year. Anthony negotiated — and Achilles agreed — to a 5-year workmanship warranty for this project. This isn’t a marketing gimmick: a contractor willing to back their work for five years is a contractor confident in the quality of their installation. It also reflects the decision to install the 115mil membrane system — a heavier, more durable choice that supports a longer warranty commitment.
The Process: Full Tear-Off, Siding Integration, and Scupper Reflashing
Step 1 — Tear-off and deck inspection
The existing flat roofing system was removed down to the roof deck. Achilles inspected the decking and replaced any damaged or rotted plywood sheets (up to four included; additional at $85/sheet) before any new materials were installed. Starting with a sound deck is non-negotiable for a system that will carry a 5-year workmanship warranty.
Step 2 — ISO insulation installation
Polyisocyanurate (ISO) insulation board was installed across the prepared roof deck. ISO board is the industry standard for flat roofing insulation — providing thermal performance, dimensional stability, and a flat, even substrate for the TPO membrane above.
Step 3 — 115MM Carlisle TPO flat roof membrane installation
The 115mil Carlisle TPO membrane was fully adhered (glued) to the ISO insulation surface. The system was installed in accordance with Carlisle manufacturer recommendations — ensuring the installation meets the requirements for manufacturer warranty documentation upon completion.
Step 4 — Siding removal, wall waterproofing, and reinstallation
One of the more complex aspects of this project was the wall-to-roof transition. Achilles removed the siding as needed, extended the TPO membrane vertically up wall surfaces to create proper waterproofing transitions, installed termination bar and water block sealant at all wall terminations, then reinstalled the siding upon completion. This step ensures that water cannot travel behind the membrane at the roof-to-wall junction — one of the most common failure points in flat roofing systems.
Step 5 — Scupper and overflow drain reflashing
Existing roof scuppers and overflow drains were reflashed to integrate fully with the new Carlisle TPO system. All flashing transitions, penetrations, and terminations were sealed to provide a continuous, watertight roofing envelope. Drainage components were confirmed functional and unobstructed upon completion.
The Full Project Timeline
Here is the complete timeline from first contact to paid invoice:
| Date | Milestone | Details |
| Jun 15, 2026 | Lead — estimate requested | Anthony C. submits request for roofing and exterior renovation estimate at Eagle Street. |
| Jun 16, 2026 | Estimate issued | Ahmad Faiz sends detailed estimate. Anthony asks about 60mil vs 80mil TPO, manufacturer, and warranty. Ahmad confirms Carlisle system, upgrade to 80mil, 5-yr warranty with 80mil upgrade. |
| Jun 16, 2026 | Upgrade negotiated — 115MM | After email exchange, Anthony agrees to upgraded scope. Achilles delivers 115mil fully adhered Carlisle TPO with 5-year workmanship warranty and veteran discount. |
| Jun 16, 2026 | Estimate signed | Anthony electronically signs Estimate. Work scheduled for Saturday, June 20, weather permitting. |
| Jun 20, 2026 | Installation completed | Full tear-off, ISO insulation, 115MM Carlisle TPO membrane, siding integration, and scupper reflashing completed. Project photos uploaded same day. |
| Jun 23, 2026 | Invoice paid in full | Invoice settled |
| Jun 24, 2026 | Phase 2 estimate issued | Estimate issued for Ground Smart Smart Loc rubber paver walkway system over completed TPO. Anthony reviewing — Phase 2 in progress. |
Honoring Those Who Served: Achilles Roofing’s Veteran Discount
When Anthony asked whether Achilles Roofing offered any discounts for disabled veterans, Ahmad Faiz confirmed a veteran discount — applied directly to the project.
It’s a small number in the context of a project. But the principle matters: Achilles Roofing & Exterior recognizes and honors the service of disabled veterans, and has a standing discount in place for qualifying homeowners. For veterans in the Greater Houston area navigating roofing projects, it’s worth asking.
The Result: A Premium Flat Roof System, Completed in One Day
By the end of June 20, 2026 — just four days after the estimate was signed — Anthony’s Eagle Street home had a brand new 115MM Carlisle TPO roof: fully adhered, fully waterproofed at all wall transitions and drainage points, and backed by a 5-year workmanship warranty.
The project was completed in a single installation day, paid in full three days later, and a second phase is already in progress: a Ground Smart Smart Loc rubber paver walkway system to create a finished, usable walking surface over the completed TPO membrane.
Before After
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Frequently Asked Questions
What is Carlisle TPO flat roof and why is it used in Houston?
Carlisle SynTec is one of the most respected manufacturers of commercial and residential TPO (Thermoplastic Polyolefin) roofing membranes. Their systems are engineered for UV stability, heat weldability, and performance under extreme temperature cycling — all critical factors in Houston’s climate. Carlisle TPO systems are used by professional roofing contractors for both commercial and residential flat roofs because they provide reliable manufacturer warranty documentation and consistent quality control across all system components.
What is the difference between 60mil, 80mil, and 115mil TPO?
TPO membranes are measured in mil (thousandths of an inch) of thickness. A 60mil membrane is standard entry-level; an 80mil provides greater puncture resistance and is often required for commercial applications; a 115mil is the heaviest standard option, offering maximum durability, dimensional stability, and a longer service life before replacement. For a residential flat roof in Houston that will experience regular thermal cycling and occasional foot traffic, a 115mil fully adhered system represents the highest-performing choice.
What is a fully adhered TPO system vs mechanically fastened?
A fully adhered TPO system is bonded directly to the substrate (ISO insulation or roof deck) across the entire surface using adhesive. A mechanically fastened system uses screws and plates at set intervals to hold the membrane. Fully adhered systems provide greater wind uplift resistance, eliminate discrete fastener locations that could become water entry points over time, and create a more uniform bond that resists billowing and movement. For residential flat roofs in Houston’s hurricane-prone climate, fully adhered installation is the more conservative and higher-performing choice.
How long does a flat roof replacement take in Houston?
A residential flat roof replacement in Houston typically takes one to two days for installation, depending on the size and complexity of the roof. Achilles Roofing completed the full tear-off and 115MM Carlisle TPO installation at a Midtown Houston home on Eagle Street in a single day (June 20, 2026). From the signed estimate to the completed, paid project was four days total.
Do Houston roofing companies offer discounts for disabled veterans?
Yes — Achilles Roofing & Exterior offers a discount for disabled veterans on qualifying roofing projects. If you are a veteran homeowner in the Greater Houston area, ask about the veteran discount when requesting your estimate.
What is the standard workmanship warranty for flat roof replacement in Houston?
Most roofing contractors offer a 1-year workmanship warranty on flat roof installations. Achilles Roofing & Exterior extended a 5-year workmanship warranty on the Carlisle 115MM TPO installation at Eagle Street — reflecting both the quality of the installed system and the contractor’s confidence in their work. This is in addition to the manufacturer’s warranty documentation provided by Carlisle upon completion.
How much does a flat roof replacement cost in Houston?
The cost of a flat roof replacement in Houston varies based on roof size, membrane thickness and manufacturer, insulation requirements, complexity of flashing and drainage work, and warranty level. Contact Achilles Roofing & Exterior for a free inspection and estimate tailored to your specific property.
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