SureCoat Metal Roof Restoration
JemStar Construction completed a 530 square metal roof restoration over 2 corrugated metal roofs at CMI Logistics LLC, a leading intermodal distribution company in the metals industry.
The corrugated metal roofs had a mineral cap sheet attached to them that was completely deteriorated to the point that it was falling off the roof surface. The exposed deteriorating asphalt roofing suffered from abrasion and was delaminating entirely. Beneath the built-up roofing materials, the metal roof was also being damaged, creating rust at penetrations, panels, lap joints and fasteners in various places throughout the roof. Leaks were entering the metal roof at the attachment screws and lap joints. The leaks began to rust and damage the structural steel supports of the building and the rain gutters were full of the deteriorated asphalt roofing and rusted beyond repair.
The annual roof maintenance inspection in August of 2015 reported that the roof was still serviceable but only if the loose cap sheet was removed, fasteners tightened and sealed and the metal surface treated and sealed with the SureCoat Roof System. By September 2015, Alden Management had a proposal from JemStar Construction and by January 2016, the metal roof restoration was underway.
In preparation for the installation, JemStar Construction first installed 575 lineal feet of safety lifeline in the ridge of both the metal roofs that the construction crews were going to be working on. Next, the rusted and damaged rain gutters at the exterior perimeter of the building were removed and scheduled to be replaced with new custom metal rain gutters toward the end of the project.
The roof was scraped to remove the existing deteriorated mineral asphalt cap sheet roofing materials. Then the roof was scraped again and cleaned to remove the loose and peeling adhesive and roof mastics from the corrugated metal roof panels.
The prep work on this roof included checking and tightening all of the roof fasteners. All broken or damaged fasteners were replaced as needed. Then all roof fasteners were cleaned with a wire brush or wire wheel and SureSkrub was used to remove dirt and grime. The loose roof panels and flashings were also fastened as needed.
The JemStar crew then cleaned and sanded the rusty metal flashings and inspected the remaining roof panels addressing splits, cracks and rusted areas. Once the metal roof repairs were completed, the crew cleaned, prepped and sealed the metal equipment curbs in the center of the building’s structure. A rusty metal primer was first applied to rusted areas of the metal surfaces. The curb to roof connection was sealed with SureCoat and Poly-Mesh; adding a finish coat of SureCoat to create a 4-ply coating repair to this area.
SureCoat and Poly-Mesh were then applied to all roof penetrations and roof flashings to prevent cracking in preparation for a complete metal roof restoration. SureCoat and Poly-Mesh were also used at visible cracks and splits to repair the metal.
All fasteners and screws in the roof surface were pretreated with a dollop of SureCoat and then sprayed with a basecoat of SureCoat covering the fasteners and lap joints throughout the field of the roof.
Once these areas were dry, a basecoat of SureCoat was applied to the entire metal roof surface at a rate of 2 gallons per 100 sq. ft. The following day, a topcoat of StrucSureCoat in storm Cloud gray was applied at a rate of 1 gallon per 100 sq. ft.
These restored metal roofs now have a 10 year renewable manufacturer’s performance warranty. These roofs can easily be renewed in year 10 for a portion of the initial installation cost and the warranty extended for an additional 10 years.
SureCoat adheres to all types of metals including factory-coated metal, galvanized, bonderized, mild steel, sheet metal and aluminum. SureCoat can be used to seal and recondition exposed HVAC ducts, plenums and flashings to stop rust, increase energy savings of the HVAC and to waterproof these problem areas. SureCoat forms a seamless, protective, waterproof membrane that moves with thermal cycles and stops oxidation to metal. Without moisture and air, the oxidation process is interrupted so rust no longer forms on the metal.
SureCoat is a cool roof coating with exceedingly high energy efficiency that lasts! Unlike many roof coatings, SureCoat retains almost all of its original values even after years in service. SureCoat has a total Solar Reflective Index (SRI) of 111%, emitting 93% of heat back into the atmosphere and reflecting up to 88% of the suns damaging UV rays.
To learn more about the SureCoat Roof System for metal roof restorations, call or click today 877-823-7873 – www.surecoatsystems.com.
Restoring a Gravel Roof in Hawthorne, California…
This charming little apartment building is freshly painted, elegantly landscaped and the perfect place to call home in Hawthorne, California. You would never know by looking at it, but this building suffered from chronic roof leaks for years.
Similar to the gravel roof restoration completed over the Leland church in Mississippi last year, the tar and gravel roof of this apartment building has a very low-slope and ponds water with each rain. Clear Properties was looking for a solution to their worn and leaking gravel roof when they heard about the SureCoat Roof System. After much online research and the comparing of product data and warranties, Clear Properties contacted a local SureCoat Approved Contractor for a proposal.
The gravel roof of this Clear Properties’ apartment building consisted of layers of coated felt that was built up and sealed together with asphalt bitumen. The asphalt was then covered with a layer of gravel to protect it from harmful UV rays. UV and ponding water are two of the most damaging elements to asphalt roofing materials.
Once a gravel roof is weathered and brittle, walking on the roof to perform leak repairs only increases the chances of developing more roof leaks. It is easy for the gravel to puncture the dried out asphalt membrane during routine roof maintenance. The gravel hides the surface of the roof and often creates a water dam that allows water to pond for long periods of time. A leak can even appear to be in the same area of the roof that has already been repaired because water will always find the weakest point of entry and travel. Flat and low-slope gravel roofs are some of the most difficult roof systems to detect roof leaks in and then repair. Years can be spent chasing the leaks in gravel roofs.
The owners of this apartment building had previously contracted with several different roofers in an effort to fix the re-occurring leaks. Unfortunately, no roof repair lasted long. Prior to the installation of the SureCoat Roof System, this roof was repaired with several different products. In one large area of the roof, the gravel was swept away and coated with an inferior white coating. The owner had been persuaded to use an expensive silicone product that by all accounts was installed correctly only to discolor and blister. This compounded their roof leak issues as no other roof coating would stick to the blistered and peeling silicone surface.
To avoid the need for re-roof, the SureCoat Approved Contractor heated and ground off the silicone and then scraped the remaining area to allow for a fully reinforced SureCoat Roof System to be properly installed. The roof was then scrubbed with SureSkrub and power rinsed completely prior to the roof repairs and installation of the SureCoat Roof System.
The SureCoat Roof System saved Clear Properties thousands of dollars over a traditional re-roof. Best of all, the aggravation of the continuous roof leaks was completely eliminated. Now the roof is as trouble free and well-kept as the rest of the apartment complex.
The maintenance crew of Clear Properties later attended one of SureCoat Systems’ monthly training classes in Anaheim, California. During training, the Clear Properties technicians were educated on the SureCoat Roof System and shown how they are able to use SureCoat products to maintain the roofs of their other properties that are still waiting on roof budgets.
There are few options for restoring a gravel roof; luckily SureCoat is one of them!
- Gravel roof prevented the roof surface from being exposed, hiding cracks and failures in the roof membrane
- Silicone repairs, no other product would adhere to the silicone roof coating repair
- Tenants in the building; noise and smell concerns
- Remove the gravel ballast material, spud the remaining embedded gravel to eliminate any protrusions or sharp edges that might compromise the system when under foot traffic
- Prepare the roof surface for the application of the SureCoat Roof System by scrubbing the roof with SureSkrub and power rinsing the roof clean
- Apply primer to rusty metal flashings and exposed equipment curbs and apply the SureCoat and Poly-Mesh at all roof penetrations
- Install a 60 mil DFT, 2800 psi tensile strength, fully reinforced SureCoat Roof System with a 10 year renewable, non-prorated warranty
The SureCoat Roof Restoration System is the longest lasting roof coating system for worn out gravel roofs. By using the existing roof as a base, the SureCoat Roof System can add an additional 10-20 years of life back into an existing gravel roof without the need for a roof tear-off. The SureCoat Roof System brings new life to old gravel roofs.
This building now has a roof system with a written warranty that is non-prorated, covers leaks in roof ponds and is renewable with maintenance applications at the end of each 10 year warranty period.
Click here to contact SureCoat Systems or call
877-823-7873 for installation and pricing information.