September 11, 2025
At its New Windsor, NY facility, Anheuser-Busch InBev operates one of the nation’s busiest can production plants, manufacturing more than 12 million cans per day. When the time came to replace the plant’s aging roof system, Hayden Building Maintenance Corp. was entrusted with the project.
The scope called for a full 163,000 sq. ft. roof removal and replacement, performed under the strictest operational requirements. To protect continuous production, Hayden implemented advanced interior protection measures and staged work around a demanding schedule that allowed no disruption to the client’s 24/7 operations.
Working under the guidance of Professional Service Industries, Inc., Hayden installed a Sika Sarnafil EnergySmart® Roof — a 60 mil, mechanically attached membrane designed for long-term durability and energy efficiency. Despite a two-month winter deadline and the complexity of hundreds of penetrations across the roof, the project was completed in just 53 days — 11 days ahead of schedule. The achievement was recognized with Sika Sarnafil’s 2010 Contractor Project of the Year Award in the Low Slope Category.
Executing a roof replacement at one of the nation’s busiest production facilities came with extraordinary challenges. The New Windsor plant operates around the clock, producing 12 million cans per day, which meant that any disruption to operations was unacceptable. Hayden’s crews needed to work within a live manufacturing environment where safety, cleanliness, and operational continuity were non-negotiable.
The project was further complicated by seasonal timing. With only two months to complete the work before year-end, Hayden had to manage unpredictable winter conditions while adhering to a firm December 31 deadline.
From a technical standpoint, the roof itself presented significant hurdles. The system spanned 163,000 sq. ft. and included more than 400 penetrations, along with extensive HVAC units, vents, and gas lines that all required careful detailing. In addition, the plant’s proximity to a nearby airport triggered FAA restrictions that limited crane operations, adding another layer of logistical complexity.
Finally, because the facility’s interior housed sensitive conveyor lines and automated equipment, the team had to ensure that no dust, debris, or moisture compromised production areas throughout the duration of the project.
To meet the plant’s rigorous demands, Hayden developed a detailed project plan that prioritized safety, cleanliness, and operational continuity. Crews were divided into around-the-clock shifts, with demolition work taking place between 2:00 a.m. and 7:00 a.m., followed by daytime installation crews working from sunrise until dusk. This ensured that roofing operations never interfered with production schedules.
Inside the facility, Hayden installed Tuff Wrap protection systems to shield conveyor lines, unmanned forklifts, and sensitive equipment. This barrier allowed roofing work to proceed overhead without risk of dust or debris reaching production areas.
On the roof, crews installed a new coverboard over the existing insulation before mechanically attaching a Sika Sarnafil EnergySmart® 60 mil membrane. The system was reinforced with stainless steel flashings and custom-fabricated parapet caps for long-term durability.
Where standard crane operations were restricted by FAA requirements, Hayden adapted by downsizing lifting equipment and carefully sequencing material staging to maintain compliance while keeping the project on track.
By coordinating closely with the client and consultant, Hayden maintained strict safety protocols, adjusted for shifting weather conditions, and executed the installation with precision.
Hayden successfully delivered the project 11 days ahead of schedule, completing the installation just before a major Christmas blizzard dropped 24 inches of snow across the region. Despite the aggressive timeline and winter conditions, the entire 163,000 sq. ft. roof was replaced in only 53 calendar days.
Most importantly, the project was completed with zero disruption to production. Anheuser-Busch’s facility continued to operate at full capacity throughout, with no interruptions to its 24/7 canning operations. The use of interior protection systems ensured that sensitive equipment remained safeguarded from debris, dust, and moisture.
The success of the project earned Hayden national recognition, receiving Sika Sarnafil’s 2010 Contractor Project of the Year Award in the Low Slope Category. The client praised Hayden’s ability to deliver a complex project under pressure, citing professionalism, precision, and an unwavering commitment to safety as key reasons for success.
From high-profile facilities like Anheuser-Busch to complex institutional campuses, Hayden Building Maintenance Corp. delivers results that stand the test of time. If you’re seeking a trusted partner for roofing, waterproofing, or façade restoration in New York, New Jersey, or Connecticut, we’re here to help.
Hayden Building Maintenance Corp. is a trusted commercial roofing and waterproofing contractor serving NY, NJ, and CT, since 1973. We specialize in long-term roofing solutions for private schools, industrial facilities, and commercial properties.
© Hayden Building Maintenance Corp.
All rights reserved.