As a commercial building owner or property manager, you have experience keeping things running smoothly. Between managing tenants, budgets, and maintenance schedules, you already have plenty on your plate. One thing that only adds to the trouble is finding out there are roof leaks on your property. 

Now, we all know that a leaking roof is a property owner’s nightmare and it can occur due to several reasons. But one cause behind leaks that many are unaware of is HVAC systems. 

Sounds strange right? However, this is possible. We have handled many leaks that were not due to issues with the roofing material, but due to rooftop HVAC units. 

But don’t worry — this isn’t about scaring you. It’s about helping you understand how a seemingly unrelated system, like your HVAC unit, can impact your roof’s health. By staying on top of the issue, you’ll save time, money, and headaches in the long run.

The Link Between HVAC Systems and Flat Roof Leaks

Commercial flat roofs and HVAC systems go hand in hand. Unlike sloped residential roofs where HVAC units are usually found on the ground, commercial HVAC systems often sit directly on the roof. Flat roofs are ideal for this because they provide the necessary space and structural support for heavy equipment.

Even though this setup is convenient, it creates potential risks. An HVAC system that isn’t working properly — or isn’t installed or maintained correctly — can quickly turn into a liability for the roof.

Here are some of the causes of leaks due to HVAC systems: 

Condensation Buildup:

HVAC systems naturally produce condensation as they cool or heat air. For example, the air conditioning system of the building, while cooling lets the warm air pass over the cooled coils, causing the moisture in the air to condense and drip into a pan. This pan is usually made from metal and since it constantly collects water, the panel starts to rust over time and this can lead to water falling below the system, causing leaks. 

Also, when too much water accumulates and the drainage system isn’t functioning properly, this water has nowhere to go. Over time, it pools on your flat roof, potentially seeping into cracks or damaging the roofing membrane.

Physical Damage from Vibration:

An HVAC system that is not properly maintained or mounted securely to the roofing structure can produce excessive vibrations, which creates a constant, unsettling movement throughout the structure. Over time, this constant shaking can take a toll on the roofing structure, wearing down its protective layers and compromising its durability. As a result, cracks and gaps may form, making the roof vulnerable to leaks and potential water damage. 

Improper Installation 

This is one of the most common reasons why your HVAC system would begin to leak is improper installation. If your HVAC system wasn’t installed with care, it might not be properly sealed along where it meets the roof. Gaps, faulty flashing, or uneven weight distribution can all cause problems and lead to leaks, especially during heavy rains.

Blocked Drainage Systems:

HVAC systems generate runoff that needs to flow into the roof’s drainage system, like drains or gutters. If these get clogged with dirt, debris, or excess water from the HVAC unit, the drainage system can’t handle the load. This backup causes water to pool on the flat roof, overwhelming the surface and increasing the likelihood of leaks.

Also Read: Navigating Flat Roof Leaks In WNY

Why Flat Roofs Are Especially Vulnerable

Flat roofs are built to handle a lot, but they’re more prone to pooling water compared to pitched roofs. Without the natural slope to direct water away, any issue with drainage—including HVAC-related problems—can quickly escalate.

Even a tiny puddle left over a long period of time can slowly start to break down the roof’s protective membrane, leading to leaks. When leaks develop on a flat roof, they’re harder to spot and diagnose. This is because water tends to spread out beneath the surface before making itself visible inside the building.

Warning Signs to Watch Out For Roof Leaks

If you suspect your HVAC system might be causing roofing problems, here are a few telltale signs to keep an eye on:

Water Stains on Ceilings or Walls:

Leaks often show up indoors first. Check for discolored patches, especially after heavy rain. If left unaddressed, these stains can grow, signaling worsening water damage.

Standing Water on the Roof:

Take a quick look at your flat roof after a storm. Any pooling water near the HVAC unit could indicate poor drainage. Prolonged standing water can weaken the roofing membrane, making leaks inevitable.

Unusual Sounds or Vibrations from the HVAC System:

Excessive noise might mean the unit isn’t running smoothly, potentially leading to vibrations that damage the roof. Over time, this can create cracks or stress points in the roof surface.

Mold or Musty Odors:

Roof leaks often lead to water damage that promotes mold growth—something you definitely don’t want to deal with in a commercial space. Mold not only damages materials but also creates health hazards for building occupants.

How to Protect Your Roof from HVAC-Related Leaks

Now that you know the risks, follow these practical steps to prevent HVAC problems from turning into leaks and larger issues:

Schedule Regular Maintenance

A forward-thinking approach goes a long way. Have both your HVAC system and roof inspected regularly in order to check for potential drainage issues, loose parts, or damage to the roof’s surface.

Install Protective Measures

Most flat roofing materials are not designed to withstand heavy foot traffic. During maintenance, professionals can unintentionally damage the roofing membrane, increasing its chance of leaking. To protect your roof from accidental damage during maintenance, consider adding walk pads or designated pathways around the HVAC system.

Check Drainage Systems

Make sure any condensation from the HVAC system is able to drain properly and doesn’t overwhelm your roof’s drainage setup. Clear any clogs and watch for debris that could back up the system. Also, take care of the metal plate that holds the condensed water. 

Work with Professionals

Whether it’s HVAC repair or regular roof maintenance, hire experts who understand the unique needs of flat commercial roofs. As a trusted roofing company in Buffalo, we help you identify and address potential issues early and ensure that your roof is in good shape and free from leaks.  

Inspect Your Flat Commercial Roof After Severe Weather Events

Heavy rain, snow, and wind are all common in the beautiful WNY area. However, all of these weather events exacerbate existing problems with your roof. As a local roofing company serving WNY for years, we advise you to inspect your roof at least twice a year and after any major storm. Professional inspectors will check your roof for pooling water, debris, or other signs of damage around the HVAC unit.

Related Post:  Roof Leak Repair Cost

Contact Your Premier Roof Repair Experts 

Your HVAC system and roof might seem like separate parts of your building, but they’re more connected than you might think. A faulty HVAC can create conditions that lead to roof leaks, and a leaking roof can damage your HVAC system; it’s a vicious cycle you don’t want to get caught in.

By staying proactive, scheduling regular inspections, and addressing small problems before they become big ones, you can save yourself a lot of trouble.If your roof is showing signs of damage, you have questions, or you need help with your commercial roof, look no further than the team at Buffalo’s Best Roofing Company LLC. Contact us today at (716) 276-3673 to schedule an inspection and find out how we can help you!