Older commercial buildings often have built-up roofing (BUR) systems that may contain materials requiring special evaluation before repair, restoration, or replacement work begins. Because many BUR systems installed decades ago used materials that may contain asbestos or other hazardous substances, proper testing and inspection are important before disturbing the existing roof assembly.

A common question among commercial property owners and roofing contractors is:

What testing is required before disturbing an older built-up roof?

Before disturbing an older built-up roof, property owners should evaluate whether asbestos-containing materials or other hazardous conditions may be present. If suspect materials exist, asbestos inspection and sampling by qualified professionals may be required before activities such as tear-off, cutting, grinding, or removal begin.

The exact testing requirements depend on the building’s age, roofing materials, planned work, and applicable federal, state, and local regulations.

Why Should Older Built-Up Roofs Be Tested?

Built-up roofing systems have been used on commercial buildings for many decades.

Older BUR assemblies may contain materials such as:

• Roofing felts

• Asphalt layers

• Mastics

• Adhesives

• Coatings

• Flashing materials

Some historical roofing products contained asbestos fibers because asbestos improved:

• Heat resistance

• Strength

• Fire resistance

• Durability

Disturbing these materials without proper evaluation may release airborne fibers.

What Is a Built-Up Roof System?

A built-up roof is a multi-layer roofing system traditionally made of:

• Multiple layers of roofing felt

• Asphalt or bitumen

• Reinforcement materials

• Protective surfacing

Common BUR systems include:

• Hot asphalt roofs

• Coal tar pitch roofs

• Gravel-surfaced assemblies

The number and type of layers vary depending on the installation date and roofing specifications.

Step 1: Review Existing Building Records

Before testing begins, owners should review available documentation.

Records may include:

• Original construction drawings

• Roofing specifications

• Previous roof replacement documents

• Maintenance records

• Prior environmental reports

These documents may identify:

• Roofing materials used

• Installation dates

• Previous asbestos surveys

However, records alone may not be enough to confirm material safety.

Step 2: Conduct an Asbestos Inspection

If the roof is old or contains suspect materials, a qualified asbestos inspector should evaluate the roof assembly.

The inspection typically involves:

• Identifying suspect materials

• Collecting representative samples

• Documenting material locations

• Sending samples for laboratory analysis

A visual inspection alone cannot determine whether asbestos is present.

Step 3: Laboratory Analysis of Roofing Samples

Roofing material samples are analyzed by qualified laboratories using approved methods.

Testing may identify whether asbestos is present in materials such as:

• Roofing felts

• Mastics

• Flashing

• Coatings

• Adhesives

The results help determine whether special handling procedures are required.

What Materials Should Be Tested?

Depending on the roof system, suspect materials may include:

Roofing Felts

Older roofing felts may contain asbestos reinforcement.

Flashing Materials

Some older flashing products and mastics may contain asbestos.

Roof Coatings

Certain historic coatings may require evaluation.

Adhesives and Sealants

Older bonding materials may contain asbestos.

Cement-Based Components

Roof-related cement materials may require testing.

Does Every Old Built-Up Roof Require Asbestos Testing?

Not every older roof will contain asbestos, but testing is often recommended before disturbing suspect materials.

Factors that increase the need for evaluation include:

• Older construction dates

• Unknown roofing history

• Planned tear-off work

• Cutting or grinding activities

• Major repairs

If workers will disturb existing roofing materials, determining whether asbestos is present is an important safety step.

OSHA Requirements for Asbestos in Roofing Work

OSHA regulates occupational exposure to asbestos during construction activities.

When asbestos-containing materials may be disturbed, employers may need to implement controls such as:

• Exposure assessment

• Worker training

• Protective equipment

• Regulated work areas

• Proper cleanup procedures

The required protections depend on the type and level of exposure.

How Does Testing Affect a Roofing Project Schedule?

Testing should be completed before demolition or disturbance begins.

Unexpected asbestos findings can cause:

• Work stoppages

• Additional costs

• Specialized contractor requirements

• Disposal delays

Early testing allows owners and contractors to plan properly.

What Happens If Asbestos Is Found?

If testing confirms asbestos-containing materials, options may include:

Leave in Place

If materials remain intact and will not be disturbed, they may sometimes remain.

Encapsulation

A protective treatment may be used to prevent fiber release.

Professional Abatement

Removal may be required before certain roofing activities.

The correct approach depends on:

• Material condition

• Scope of work

• Applicable regulations

Other Testing Considerations for Older Roofs

While asbestos is a major concern, older BUR systems may also require evaluation for:

Moisture Damage

Testing may identify:

• Wet insulation

• Trapped moisture

• Deteriorated materials

Roof Deck Condition

Inspection may identify:

• Corrosion

• Structural deterioration

• Damaged decking

Hazardous Materials

Some older buildings may require additional environmental evaluations.

What Should Commercial Property Owners Ask Roofing Contractors?

Before disturbing an older BUR system, owners should ask:

• Has the roof been inspected for asbestos?

• Were samples collected and tested?

• Who performed the testing?

• Are hazardous materials present?

• How will materials be handled?

A qualified roofing contractor should identify potential hazards before starting work.

Common Testing Mistakes

Assuming Age Alone Confirms Asbestos

Only proper testing can confirm asbestos content.

Starting Tear-Off Before Evaluation

Disturbing unknown materials can create unnecessary risks.

Testing Only Visible Materials

Hidden layers may also contain suspect materials.

Ignoring Previous Roof Layers

Roof overlays may hide older materials below.

Frequently Asked Question

What testing is required before disturbing an older built-up roof?

Before disturbing an older built-up roof, property owners should evaluate whether asbestos-containing materials may be present. This typically involves reviewing building records, having suspect roofing materials inspected by a qualified asbestos professional, collecting samples when necessary, and performing laboratory analysis before tear-off, cutting, grinding, or removal activities begin. Proper testing helps protect workers, comply with safety requirements, and prevent unexpected project delays.

For commercial roofing projects involving older built-up roofs, early testing and hazard evaluation help ensure safe demolition, proper planning, and successful roof replacement or restoration.

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