When and How Long: Commercial Roofing Project Start and Duration
You’ve got an upcoming roofing project. Naturally, you want to know two things: When will it start and how long will it take?
According to Jon Reiss, Vice President of Operations, and Chad Rouse, Project Manager, at D. C. Taylor Co., the answers depend on a mix of planning, coordination, and sometimes, factors outside of anyone’s control. Below, they break down what enables – or inhibits – a quick start and what determines (or sidetracks) a project schedule.
How Soon Can My Commercial Roofing Project Start?
The most straightforward factor is crew availability. Ideally, as soon as one project wraps up, that crew is reallocated to the next project in line. When transitions are seamless, projects can begin quickly; however, if crews are still tied up on other jobs – especially if those jobs encounter delays – it can push back your start date.
Sometimes the hold-up isn’t on the contractor’s end. Customers may have restrictions on when the crew can start and what days and hours they can work. Perhaps it’s a planned facility shutdown or coordination with other trades because the roof work is part of a larger project; both will influence project start.
Commercial roofing rarely happens in isolation. Multiple trades and vendors often need to align before work can begin. Availability of asbestos-containing material (ACM) abatement professionals, interior protection companies, structural contractors, and HVAC and electrical trades (to name a few) can be a determining factor. For example, if interior protection hasn’t been erected beneath the work area (or new rooftop HVAC equipment hasn’t been installed) roofing can’t proceed. Additionally, if a crane is scheduled but becomes unavailable, work may stall. Even a small disruption in this chain can shift the start date.
Weather is a major variable as well, especially in the North and Midwest. For example, fully adhered roofing systems require certain temperature thresholds. That type of project at a facility in Iowa isn’t likely to happen in January. The type of roofing system and seasonal conditions play a big role in determining when work can begin.
How Long Will My Commercial Roofing Project Take?
Estimating a timeline isn’t guesswork. D. C. Taylor Co. operations team members carefully consider:
- Project location.
- Scope of work and project complexity.
- Planned crew size.
- Realistic daily production rates.
From there, they calculate an anticipated duration, expressed in total work days.
Crew size impacts duration, but not always in a simple, linear way. Increasing from 6 to 8 workers might shorten the timeline. Dropping to 4 workers may extend it. But doubling manpower doesn’t necessarily double productivity. “Some jobs just aren’t scalable,” says Reiss. In congested areas, only 4 or 5 people may physically fit and work efficiently at a time. At the estimating stage, project managers determine what makes sense given the space and workflow constraints.
In a perfect world, crews could work 50 hours (5 10-hour days) per week. In reality, restrictions, weather, and logistics often prevent that. Options to accelerate a project include adding personnel, using different equipment, running two shifts, and working nights. The last two of these options, although possible, require additional planning and coordination. And always, the safety of crews determines what’s possible.
Why is My Commercial Roofing Project Taking Longer Than Expected?
Even the most detailed plan can be disrupted, most often by weather. Rain, lightning, high winds, and wild temperature swings can halt production. Because of this, experienced contractors prefer giving an anticipated start date and an estimated duration rather than a specific date of completion. Weather uncertainty makes firm end dates risky.
Even if weather isn’t an issue in your area, it could be elsewhere. D. C. Taylor Co. responds to occasional emergencies, especially after major storms. If a roof begins to fail or blow off at another facility, crews may need to be redirected temporarily. The company works hard to minimize the impact on existing projects while addressing urgent needs, but emergency response can sometimes affect schedules.
Natural disasters throughout the United States can also wreak havoc on material logistics. A massive recent southern storm, for example, backed up deliveries for nearly a week, impacting multiple active job sites. When materials are shipped as pallets on shared freight trucks, contractors are at the mercy of freight companies. Delays caused by storms, regional disruptions, or even truck breakdowns can stall a project for days.
Another reason a project might stretch out longer than anticipated is latent conditions (i.e., hidden issues that aren’t visible during an initial roof survey). Examples include substrate or decking damage that wasn’t known/discovered prior to project start or roof systems that were installed differently than expected. Rouse recounts a recent situation: “We thought it was a bead applied system that we were tearing off. Well, it was full spray, so tear-off took a lot longer than what we anticipated.”
Eliminating surprises altogether isn’t always possible, but thorough roof surveys, pre-construction site visits, project managers verifying “as-is” conditions, and identifying hazards (e.g., bad decking or overhead power lines) long before a project commences is a good start. Diligent pre-planning reduces risk.
Projects can take longer when the customer changes them too. Deciding to add walkway pad, install fall protection, or expand the area of work after the project begins results in change orders. This scope change also requires new materials, additional labor, and usually a longer timeline. The earlier in the project these changes are identified and agreed upon, the less impact they will likely have on delays.
Setting Expectations: Why Flexibility Matters
The key takeaway? Commercial roofing schedules are carefully planned but inherently dynamic.
Experienced contractors like D. C. Taylor Co. balance:
- Crew allocation.
- Trade coordination.
- Weather forecasting.
- Material logistics.
- Risk mitigation.
That’s why customers typically receive an anticipated start date and an estimated duration (number of workdays), rather than a guaranteed finish date.
With proper planning, clear communication, and proactive site evaluation, many potential delays can be avoided. But in commercial roofing, flexibility isn’t a weakness, it’s part of delivering the job safely and correctly.
If you have an upcoming project, early coordination and open communication are the best ways to ensure the smoothest possible start and the most predictable timeline.
Got a roofing project? Contact D. C. Taylor Co. at 319.731.4118 or email [email protected] to get your project on our schedule.
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