April 2014

Thinking long-term

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Insulated Roofing Contractors restores a roof system and applies a sustainable roof coating

by Krista Reisdorf

Whenever it rained at a Georgia department store's distribution facility, the building's 12-year-old PVC roof system would have 50-60 leaks that threatened the products inside the building.

To address the problem and find a cost-effective, high-performance roof system, the company hired Insulated Roofing Contractors, New Albany, Ind., to evaluate and test various coating options for the existing single-ply membranes that were starting to fail.

"After two years of field trials, we recommended the Silicone Roof Coating Restoration (RCR) System offered by Progressive Materials LLC," says Billy Wilkins, Insulated Roofing Contractors' national accounts manager. "The material offered excellent adhesion over most membranes without the use of a primer and provided a long-term waterproofing membrane."

Insulated Roofing Contractors, New Albany, Ind., installed a Silicone Roof Coating Restoration System on a 2 million-square-foot Georgia distribution facility.

Insulated Roofing Contractors had worked with the retailer on previous projects and was chosen to install the Silicone RCR System on the 2 million-square-foot facility.


The project began July 9, 2012.

The existing roof system consisted of a metal deck, 2 1/2-inch-thick polyisocyanurate board and mechanically attached PVC.

The company focused on first restoring the existing roof system.

"An infrared scan was completed to identify all wet insulation," Wilkins says. "At each location, the membrane was cut and removed to expose the wet insulation, which was removed and replaced. The membrane then was put back in place and mechanically attached at each seam, in addition to fasteners installed at the cut every 6 inches on center and staggered. Once the membrane was secured, the cuts were primed and stripped in with peel-and-stick material."

Depending on the detail, deficient membrane seams, mechanical damage and roof flashings were repaired using either a peel-and-stick material or silicone coating and fabric. The company then cleaned the membrane by power washing the roof.

Thirty mils of Progressive Materials’ HS3200 Series silicone roof coating was spray-applied in a single coat over the field of the roof and all flashings.

Subsequently, 30 mils of Progressive Materials' HS3200 Series silicone roof coating, which is a high-solids silicone and does not contain any solvents, was spray-applied in a single coat over the field of the roof and all flashings.

Safety precautions taken during the project included a warning-line system installed around the perimeter of the work area. Any work activities outside the warning-line system required a 100 percent fall-arrest system consisting of a full-body harness, lanyard and safety rope secured to an Occupational Safety and Health Administration-approved tie-off point. Additionally, all skylights were covered with protective cages to prevent falls.

Environmental rewards

Wilkins says the project's methods prevented challenges that often are involved with other roofing projects.

"It provided a really nice project for one of our crews," he says. "It was a nice break from the difficult jobs to which they are accustomed. Every time we have an RCR project hit the schedule now, all our project foremen beg for it."

Additionally, the RCR system eliminates 40,000 yards of waste going to the landfill because the building's existing insulation was used.

"This project was unique because of the unbelievable environmental and financial benefits of this system," Wilkins says. "We were able to restore a failing single-ply roof and use all the good insulation while providing the client with a 15-year system warranty. Being able to provide our client with a cost-effective roofing solution that performs great and provides tremendous environmental benefits was rewarding."

Krista Reisdorf is Professional Roofing's director of online communications.

Project name: Georgia department store distribution facility
Project location: Georgia (50 miles southwest of Atlanta)
Project duration: July 2012-June 2013
Roof coating type: Silicone roof coating
Roofing contractor: Insulated Roofing Contractors, New Albany, Ind.
Roofing manufacturer: Progressive Materials LLC, New Albany, Ind.


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