Transforming a Rusted Metal Roof into an Energy-Efficient Asset

An aging metal roof can pose significant challenges for industrial facilities, from structural degradation to rising energy costs. When a facility faced extensive rusting and minor leaks on its roof, leadership sought a solution that would restore durability, improve energy efficiency, and avoid the high costs of a full replacement. The answer was a high-performance acrylic coating system—a cost-effective alternative that delivered long-term protection and financial advantages.

A Strategic Approach to Roof Restoration
Rather than undergoing a complete roof replacement, which would involve substantial labor, material costs, and business disruptions, the facility opted for a restoration process designed to extend the roof’s lifespan while maximizing efficiency. The process followed three key steps:

1. Surface Preparation – The roof was pressure washed to remove rust, dirt, and debris, ensuring optimal adhesion for the new protective layers.
2. Corrosion Prevention – A high-performance rustinhibiting sealant was applied to prevent further deterioration and create a stable foundation.
3. Acrylic Coating Application – A seamless, waterproof acrylic coating was installed, eliminating leaks and enhancing the roof’s reflectivity to reduce heat absorption.

The Benefits of an Advanced Coating System
By choosing restoration over replacement, the facility achieved multiple benefits:

• Waterproof Protection – The seamless acrylic barrier eliminated leaks, strengthening the roof’s structural integrity.
• Significant Energy Savings – With the ability to reflect up to 90% of the sun’s heat, the new roof coating lowered cooling costs and improved indoor comfort.
• Financial Flexibility – Unlike a full roof replacement, which must be depreciated over decades, this restoration qualified as a maintenance expense, allowing for full depreciation in the year of installation—an immediate financial advantage.

A Lasting Impact
Following our coating application, the facility reported a substantial reduction in roof temperatures and lower maintenance costs. The existing metal roof, once at risk of deterioration, was transformed into a long-term, energy-efficient asset— delivering sustainability, savings, and superior performance.

By leveraging innovative roofing solutions, industrial facilities can preserve infrastructure, control costs, and achieve greater operational efficiency—all without the burden of unnecessary replacement expenses.

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