Industries · Warehouse & distribution
Big roofs fail by the square foot. Manage them by the square foot.
On a 300,000-square-foot roof, the difference between “replace it all” and “replace the 8% that’s actually wet” is a seven-figure decision. At warehouse scale, evidence isn’t a nice-to-have — it’s the whole game.
Schedule My Free Roof Assessment01 · The stakes
At this scale, a percentage point is real money.
Warehouse roofs are where scan-first management pays off most brutally. Replacement bids price the whole field — but saturation almost never covers the whole field. An infrared survey that maps wet insulation to specific squares routinely turns a full-replacement conversation into a targeted one. On big roofs, the scan is the cheapest square footage you’ll ever buy.
Meanwhile, everything under the roof compounds the risk: racked inventory that can’t get wet, dock operations that can’t pause, skylights and smoke hatches that age faster than the membrane around them, and insurance carriers with opinions about all of it. We plan around the operation, document for the carrier, and let the scan decide where the money goes.
02 · Built for the industry
What we plan around — and how we answer it.
The realities of a distribution roof
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Scale turns percentages into fortunes
8% wet on 300,000 SF is 24,000 SF — a project. 8% assumed everywhere is a tear-off — a catastrophe of a budget line.
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Inventory can’t get wet
Racking runs to the ceiling and the product on top takes the first drop. A pallet position leak is an inventory event.
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Operations never pause
Docks run around the clock. Staging, deliveries, and crane picks all have to happen without blocking a single door.
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Skylights, hatches & carriers
Skylights age faster than membranes, smoke hatches are code items, and your insurance carrier wants documentation on all of it.
How Lionstar answers
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Scan first, spend second
Infrared mapping by the square, verified with cores — so capital goes to the squares that are wet, not the ones a bidder assumed.
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Interior protection planned by aisle
Work zones mapped against racking below, containment where it matters, and watertight ends to every shift.
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Dock-aware logistics
Staging, deliveries, and crane picks scheduled around your dock windows — coordinated with your ops team, in writing.
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The full-envelope file
Skylights, hatches, and details inspected and documented alongside the membrane — one report your carrier and your CFO can both use.
03 · The playbook
The warehouse playbook, in order.
Large-roof economics reward owners who know their roof by the square. The sequence:
04 · Questions
Questions we hear from your desk.
Is an infrared scan really worth it on a large warehouse roof?
The bigger the roof, the better the math. A scan costs a tiny fraction of replacement and tells you what percentage of the field is actually wet — which on large roofs is routinely a single-digit number hiding inside a full-replacement bid. One mapped roof has paid for decades of scans. We’ll also tell you honestly when a roof isn’t a good scan candidate.
Can you work over racked inventory and active dock operations?
Yes — it’s the defining constraint of warehouse work and we plan for it explicitly. Work zones are mapped against the aisles and product below, interior protection is placed where the work is, every section is watertight before crews leave, and staging and deliveries are scheduled around your dock windows with your ops team.
Our insurance carrier is asking about the roof. Can you help?
That’s increasingly common, and documentation is the answer. Our assessments produce the condition evidence carriers want — scan imagery, core data, photo documentation, and maintenance records. Owners on LionCare programs hand their carrier a file instead of an argument, and it shows in how renewals go.
Warehouse & distribution
Know every square foot before you spend on one.
A free assessment starts the map: condition, moisture, and an honest read on whether that roof needs a project or just a plan. At your scale, the evidence pays for itself.
Schedule My Free Roof Assessment651-780-7663 · info@lionstarcommercialroofing.com