From Leaks to Longevity
The Roof Retrofit That Transformed a Major Bottling Facility
by Melissa Hubbell, Marketing Communications Manager, Duro-Last
Nestled at the base of the majestic Mount Shasta in Northern California, the Crystal Geyser® Natural Alpine Spring Water® bottling facility is a cornerstone of the company’s global operations. The facility bottles spring water directly from the pristine Shasta National Forest, where it is sourced from deep within the mountain’s natural reserves. This massive operation, responsible for producing and shipping bottled water worldwide, depends on a well-maintained facility to ensure efficiency and product purity. However, persistent roofing failures threatened its ability to operate without disruption.
The Crystal Geyser team had long battled significant water intrusions in the facility’s aging low-slope metal roof, threatening strict sanitation protocols and posing a serious risk to production. Seeking a solution, the company previously invested in a roof coating system, but it failed to deliver the promised protection. Frustrated with ongoing issues and wary of additional investments, Crystal Geyser hesitated to trust another contractor with such a crucial project.
Pressure Point Roofing of Central Point, Oregon, was brought in through a recommendation from its Duro-Last® sales representative. Recognizing the skepticism from Crystal Geyser’s team, Pressure Point Roofing took a proactive approach in building trust. The Pressure Point team arranged for a tour of the Duro-Last manufacturing facility in Grants Pass, Oregon, allowing Crystal Geyser leaders to see firsthand the durability and quality of the products. Combined with Pressure Point’s three decades of expertise, this effort convinced the company to move forward with a phased roofing solution. “Earning their trust was key,” said Matt Stone, president of Pressure Point Roofing. “They had been burned before, so we had to show them not just with words but with action that we could provide a lasting solution.”
The project was executed in three phases. The first phase, completed over four weeks in 2023, tackled the most critical leak-prone areas. Pressure Point Roofing installed a complete metal retrofit system, starting with Duro-Guard® Flute Fill insulation to level out the existing metal roof. Next, a 2.6-inch Duro-Guard ISO insulation board was applied to improve energy efficiency and provide a solid substrate. The roofing system was then finished with Duro-Last 50 mil white membrane, attached using Duro-Bond® induction welding system, which provided superior wind resistance. This was a crucial feature, as the facility regularly experiences wind speeds between 80 and 100 mph.
After seeing the results of phase one, the Crystal Geyser team was convinced of the system’s effectiveness. “They told us they checked every inch of that roof, looking for any sign of leaks, and they found nothing,” said Larry Sykes, Sales and Marketing Manager at Pressure Point Roofing. “That was the moment we knew they were fully on board with the system. It performed exactly as we promised, even through extreme winter conditions.”
The second phase, completed over six weeks in 2024, expanded this same retrofit system across additional sections of the facility’s roof. Pressure Point Roofing continued using the Duro-Last membrane along with EXCEPTIONAL® Metals edge details to ensure a watertight perimeter. As a final touch, the Pressure Point team installed the Crystal Geyser logo on the rooftop using red and blue membrane to match the company’s branding. This customization not only enhanced the facility’s aesthetics but also demonstrated the precision and versatility of the Duro-Last system.
The third and final phase, scheduled for 2025, will complete the main facility’s roof system, totaling 227,000 sq.ft. of coverage. This final stage will follow the same installation process, ensuring consistency and performance across the entire structure.
Given the facility’s location near Mount Shasta, Pressure Point Roofing had to work within a narrow seasonal window to avoid extreme winter conditions. Heavy snowfall can begin as early as October, limiting construction to the summer and early fall months. Additionally, high winds frequently posed challenges during installation, requiring precise coordination to keep materials secured and the project on schedule.
Beyond roofing, Pressure Point Roofing also identified and resolved additional water intrusion issues throughout the facility. The team installed new flashing above windows to prevent ice buildup and sealed wall bases where water had been infiltrating. In an area with heavy snowfall and ice accumulation, these measures provided long-term protection for the facility’s infrastructure. “They trusted us to not only fix their roof but to help them protect their entire operation,” said Stone. “That’s the kind of partnership we strive for.”
Backed by a 20-Year NDL warranty from Duro-Last, the Crystal Geyser team was so satisfied with the results that it extended the partnership with Pressure Point Roofing. The company has already committed to Duro-Last roofing on a new facility expansion in the near future.
“This project wasn’t just about fixing leaks, it was about giving them peace of mind,” said Sykes. “They had been through so much frustration before and now they know they have a system they can rely on. We’re really proud of the relationship we’ve been able to build with their team based on the quality of the product and our work.”
