In Fountain Valley, on Mount Washington Street, a quiet aerospace machine shop turns out parts that fly on some of the nation's most demanding programs. Avatar Machine, LLC has specialized in high-precision CNC machining since 2008 - a family-owned, ITAR-compliant shop certified to ISO 9001 and AS 9100, trusted by aerospace and defense partners for work where a thousandth of an inch matters. Their recognition includes United Launch Alliance's Small Business Excellence Award and multiple NASA Orion Program Manager's Commendations spanning EM-1, EM-2, and Artemis I.
When that kind of work happens under one roof, the roof itself is part of the production line. In 2023, BYLTup was entrusted with replacing Avatar Machine's aging flat roof with a modern IB Roof Systems PVC assembly - not as a cosmetic upgrade, but as infrastructure for a shop that cannot afford water, heat load, or downtime above its precision equipment.
This was far more than a standard commercial re-roof. It was a facility-protection project shaped around Avatar's goals: a long manufacturer-backed warranty, reliable cover over extension-precision manufacturing equipment below, higher energy efficiency to cut electricity cost, a solar-ready roof for the future, easier maintenance beside a neighboring concrete processing facility, and new Lane-Aire skylights to bring natural daylight into the shop.
Project Overview: Protecting Precision Manufacturing From the Top Down
Avatar Machine's Fountain Valley building sits in an active industrial corridor. The existing roof was an old cap sheet system that had reached the end of its useful life. Below it sits the kind of CNC capacity and aerospace workflow that depends on a dry, stable envelope - and on a roof that can be maintained without turning every service visit into a risk.
BYLTup's Fountain Valley commercial crew executed a full tear-off and IB system installation while keeping the stakes clear: protect the shop floor, improve the building's thermal performance, and leave Avatar with a roof that supports the next chapter of the business.
Key Project Highlights:
- Complete demolition of the existing cap sheet roof
- Repair of rotted and damaged lumber decking where needed
- New 1/4" DensDeck cover board
- Installation of a premium 50 mil white single-ply PVC IB Roof System
- Eight new scuppers as part of the drainage detailing
- Rebuilt AC curbs as part of the waterproofing detailing
- Four new curb-mounted Lane-Aire double-dome skylights for natural daylighting into the manufacturing space
- Full 20-year manufacturer-backed No-Dollar-Limit (NDL) warranty from IB Roof Systems (Warranty #C-24-030097)
- Reflective white membrane chosen for energy efficiency and long-term cool-roof performance
- Roof assembly planned with future rooftop solar in mind
- Cleaner, more durable surface for ongoing maintenance next to a concrete processing neighbor
Coordination Built Around a Working Shop
Precision machining does not pause easily. The project required careful staging so tear-off, deck repairs, and membrane work protected the building envelope while Avatar's operations continued below. Detailing at curbs, penetrations, and transitions mattered as much as the open field of roof - because that is where industrial buildings usually fail first.
BYLTup approached the job as commercial roofing for a production environment: control dust and debris where possible, sequence work for weather windows, and leave a finished membrane that can be walked and maintained without inviting damage from industrial surroundings.
Step-by-Step Roofing Transformation
1. Demolition & Tear-Off
The crew carefully removed the old cap sheet roof down to a sound substrate, clearing failed material so the new system could be built on a clean, inspected deck rather than over layered problems.
2. Structural Prep & DensDeck
Where lumber had rotted or taken damage, repairs were made before cover board. A new 1/4" DensDeck layer created a stable, fire-resistant substrate for the IB membrane and a better base for long-term warranty performance.
3. IB Single-Ply PVC 50 Mil Roof System
The centerpiece is the new IB Roof Systems 50 mil white PVC membrane - a high-performance single-ply solution known for weld strength, chemical and UV resistance, and reflective energy performance. For Avatar, that white field is more than appearance: it helps reduce heat gain into a shop that already runs energy-intensive CNC equipment, supporting their goal of lower electricity cost over the life of the roof.
4. Drainage, Curb Rebuilds & Penetrations
Eight new scuppers and rebuilt AC curbs tightened common failure points on a working industrial roof, giving mechanical equipment and drainage clean, warrantable transitions into the new membrane.
5. Lane-Aire Skylights for Natural Daylighting
Four curb-mounted Lane-Aire double-dome skylights were installed on new 2x8 curbs to bring natural light onto the manufacturing floor - improving the day-to-day working environment while keeping the envelope weather-tight.
6. Maintenance-Ready Finish Next to Heavy Industry
Beside a concrete processing facility, a roof has to tolerate dust, foot traffic for service, and real-world maintenance. The finished IB system gives Avatar a durable, cleanable surface and walkable detailing that supports easier upkeep without sacrificing the waterproofing layer below.
Finished Roof: Warranty, Efficiency & Room to Grow
The completed roof is a commercial IB assembly matched to how Avatar Machine actually works. The 20-year manufacturer-backed NDL warranty (IB Warranty #C-24-030097) answers their need for long-term coverage. The reflective 50 mil PVC membrane supports energy efficiency over a heat-sensitive, equipment-dense floor. The detailing is built for maintenance in an industrial neighborhood. And the roof is positioned for a future rooftop solar add - so Avatar can keep improving the building's operating cost without redoing the waterproofing first.
For a shop whose parts support launch vehicles, Orion hardware, and next-generation aerospace programs, the roof is not an afterthought. It is protection for the precision manufacturing that happens underneath it - and a platform for the efficiency and solar goals still ahead.
Historic landmarks and high-precision manufacturers both need roofing partners who understand what is at stake below the membrane. At Avatar Machine in Fountain Valley, BYLTup delivered an IB Roof Systems solution that respects aerospace-grade operations while giving the building modern performance, daylight, and a clear path toward lower energy cost and future solar. With a full 20-year NDL warranty, Avatar can keep focusing on CNC precision - knowing the envelope above the shop is built for the long term.