NASA Glenn Research Center

The View: Nasa Aerospace Communications Facility

Roof Replacement Under High Scrutiny & Complex Conditions

The NASA Glenn Research Center project involved the full replacement of a recently installed roofing system that had failed prematurely—bringing elevated scrutiny, pressure, and oversight from both NASA and the general contractor.

Warren Roofing stepped in to not only deliver a high-performance replacement system, but also help investigate failure points and restore confidence in the building envelope.

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The Job

Full Roof Replacement & System Correction

This project required the removal and replacement of a failed roofing system on a fully operational aerospace facility.

Originally planned as a phased demolition followed by installation, the approach had to be reworked due to site conditions. The flat roof deck and temporary exposure created persistent ponding water issues, requiring constant management.

Additionally, the scope expanded to include a custom solution for transitioning rooftop pavers to a door threshold—something not originally addressed in the base project plan.

The Challenge

Working Under Pressure—And Under A Microscope

From day one, this project carried significant pressure.

The failure of the original roof system meant that every step of the replacement was closely monitored. NASA and the general contractor maintained full-time oversight—not only to ensure proper installation, but also to investigate the root cause of the original failure.

Environmental conditions added another layer of complexity. The flat deck and temporary roofing conditions led to daily water management challenges, requiring crews to constantly pump water and maintain watertight seals.

The Team

Commercial Roofing Crew & Project Partners

Collaboration: Warren Roofing, General Contractor, NASA Oversight

Support Partners: Material Suppliers, Scaffco Scaffolding

Environment: Active Aerospace Facility

Success required coordination not just within the crew, but across all stakeholders—balancing execution with investigation and accountability.

The Process

Adapting In Real Time To Protect The Project

As challenges emerged, the team adapted quickly.

The original plan was restructured to complete demolition and installation within the same day—reducing exposure to weather and minimizing water intrusion risks.

Daily housekeeping and proactive leak prevention became critical, with crews maintaining tight control over the work environment.

A key innovation came in the development of a custom paver transition system. Working with suppliers, the team created a substrate solution that allowed equipment to be rolled onto the roof while maintaining proper drainage.

Custom metal closures were also fabricated to address wind uplift concerns and protect the system from UV degradation—ensuring long-term performance.

Safety Approach

Secure Access & Controlled Jobsite Conditions

Safety and security were critical due to the sensitive nature of the facility.

With the building fully occupied, roof access through the interior was not permitted. To address this, the team partnered with Scaffco Scaffolding to install an external stair tower—providing safe, controlled access without disrupting operations.

Strict adherence to site protocols ensured both crew safety and compliance with NASA’s security requirements.

The Results

Restoring Performance—And Trust

Despite the challenges, the project was completed successfully—delivering a high-quality roofing system that met stringent performance expectations.

The client was extremely satisfied with the final result, recognizing the team’s ability to perform under pressure and deliver where the previous system had failed.

Beyond installation, Warren Roofing played a key role in helping NASA and the general contractor better understand the causes of the original failure—adding value beyond the scope of work.

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