A Roof Coating Is the Right Answer for Florida Condo Complex

Photos: KARNAK Corporation

Educated customers make the best decisions.

That philosophy is shared by Frank Scelzi of Munyan Restoration Waterproofing and Painting Service of Tampa Bay Inc. The company was founded in 1951 as a painting and waterproofing company, and over the years it has evolved into a general contractor that handles restoration of the entire building envelope, including the roof.

Munyan Restoration often educates its customers through seminars, which sometimes have the added benefit of bringing in new business. According to Scelzi, that was how he got involved in the Sage Condo project in St. Petersburg, Florida. “We have a marketing department, and we do what’s called ‘lunch and learns,’” he says. “Our engineer also has several continuing education classes approved for facility managers and building owners who want to keep up to date on certain things. We have these several times throughout the year, and one of the property managers said he needed a roofing inspection.”

The property manager was worried that his roof needed to be replaced, and he asked Scelzi to take a look. Scelzi found the existing TPO roof was nearing the end of its service life, and it had some minor tears and punctures, but he believed the roof would be a good candidate for a restoration coating. He contacted Joe Prussel, Southeast U.S. Regional Manager for KARNAK Corp., to confirm his conclusion and determine which product would be the best fit.

“After the initial evaluation, Frank brought me back to walk the roof and look at the condition of it,” Prussel says. “Frank wanted to give them an option of coating in lieu of tearing everything off and transporting all of the trash to the dump — avoiding not only the cost but the environmental impact that would have, as well as the disruption to the residents that live there because the building has a multi-level roof.”

After adhesion tests proved a high-solids silicone coating would be an excellent fit, Scelzi submitted a written proposal and he and Prussel put on a presentation for the board and the property manager. “We told the board that we’ve been on the roof and had seen the damage that is up there, and we feel that it is a good candidate for a coating application,” Scelzi recalls. “We went through the procedure with them. We told them how we clean the roof, how we do our repairs, apply our primer, do our tie-in work, and ultimately apply the coating.”

After he detailed the safety plan and documented the experience and training of his crews, Scelzi told the residents what to expect during the coating application, stating, “There’s really going to be no disruption of your lifestyle while the coating system is going on.”

The board had been budgeting for a roof replacement, and the coating application was substantially less expensive. It would also be approved for the 20-year warranty the board sought. “They decided to go forward with it,” Scelzi says. “This was a real quick turnaround, which is unusual in the condo market. We were at a board meeting on a Thursday night and had a signed contract Friday morning.”

Following the Plan

A couple of weeks later, the Munyan Restoration crew was executing the plan laid out at the board meeting.

The building had a main roof on the 12th floor and two other roof sections on the fifth floor, totaling approximately 30,000 square feet. The main roof was sloped toward the interior, and its outer edges were approximately 6 feet above the center. “Everything slopes into the roof’s interior to make it more architecturally pleasing,” Scelzi notes. “It gave you a real weird feeling when you stepped out on that roof, but as far as setting up a safety perimeter, it made things fairly easy. The roof also had built-in tie-off points, so our guys could be harnessed, and that made the safety aspect very easy for the guys up there.”

The roof on the Sage Condo complex was restored using a high-solids silicone coating system manufactured by KARNAK. Photos: KARNAK Corporation

The first step was washing the roof with 799 Wash-N-Prep, an environmentally safe cleaner that can go right into the roof drains and the water system. “The entire roof was cleaned,” notes Scelzi. “We used a power washer and a round scrubber head that really raises the dirt from the roof. The roof was pretty dirty, but it really came out very, very clean and it was a real good surface for us to do our repairs and start doing our tie-in work.”

Repairs were made to seams and penetrations using Karna-Flex 505 WB repair mastic with fibers, using a brush application. The next steps included applying the primer and the coating.

The 180 Karna-Sil Epoxy Primer is a two-part epoxy that can be applied with spray equipment or a roller. A roller was used on this project, and it was applied at a rate of 3/4 of a gallon per square. “It really enhances the adhesion of the coating to the roofing membrane,” notes Prussel. “This is one of the products we did an adhesion test with and got very good results. It dries fairly quickly — in three to four hours — which makes it very user friendly.”

After the primer was dry, the Karna-Sil 670 high-solids silicone coating was applied. The product was chosen for several reasons, including its excellent performance in the adhesion test and the fact that the owner wanted a white coating. The product also allowed the contractor to meet the 20-year warranty with only one coat, minimizing labor costs.

The slope of the roof was another key consideration, as crews wanted to make sure the product didn’t run or migrate when they put it on. “What was really nice about this system from KARNAK was the high-solids silicone, even with the angle of the roof, the coating just stayed there, so we could really get our millage,” notes Scelzi. “On this job, we even exceeded it in some areas, which was good.”

For the 20-year specification, the coating was applied at a rate of 3 gallons per square, or 46 dry mils. As they put the coating down with rollers, crew members constantly checked the thickness with a mil gauge. After the project was completed, destructive testing confirmed the proper mil thickness was achieved, and then the test areas were repaired.

Smooth Operation

Weather was a concern, as rain, dew and fog are common in the area. “We had a couple of days we had to stand down due to the weather, but other than that, the project went very smoothly,” Scelzi says. “It really shows you what coatings are supposed to do — make it more friendly for the building owners and for the applicators who put it down.”

It also minimizes disruption for the residents. “We had some material we had to stack in certain areas, but the residents never even knew we were there unless they saw that material,” Scelzi says.

Prussel points out that coating applications also pose less liability for owners, as the roof area is never exposed to the weather, as it would be during a tear-off. “With a coating, there is never a liability of an open roof, and especially in Florida in summertime, you never know when you’re going to get some rain.”

Feedback on the job has been positive, notes Scelzi. “The owners, property manager and board members are very happy,” he says. “It’s a nice, clean-looking product and there are no seams. It’s a monolithic system. They are very pleased with the result, and it cost a lot less than a roof replacement.”

The project included a contract for an annual maintenance program. According to Prussel, proper maintenance not only safeguards the warranty, it can save owners money in the long run by ensuring the likelihood that the roof will be a good candidate for another coating application when the warranty period nears its expiration.

“Whenever we do a presentation for a building owner, a board, or a property manager, we always stress the importance of maintenance,” Prussel says. “It’s extremely vital to any roofing project, be it a coating or a new membrane, that a certified applicator of that manufacturer observe the roof a minimum of once a year, maintain it, make any repairs, and make a report for the owner.”

Scelzi and Prussel believe that teamwork between the manufacturer and the contractor is essential at every phase of the job. “As the manufacturer working with the applicator, we have a technical support team that can advise the applicator which product would be the best fit for that substrate,” says Prussel. “We are there to specifically design a system that is the best fit for the owner of that building, and we can advise the contractor on the application, and they can lay out the best option for that customer. We want to make sure our product will work, our product will last, and everybody will be happy.”

Scelzi agrees. “It gives the customer a good feeling to know they have a quality contractor and a quality manufacturer standing behind them,” he says.

TEAM

Roofing Contractor: Munyan Restoration Waterproofing and Painting Service of Tampa Bay Inc., Clearwater, Florida, www.munyanpainting.com

MATERIALS

Roof Coating: Karna-Sil 670 high-solids silicone, KARNAK, www.karnakcorp.com

Primer: 180 Karna-Sil Epoxy Primer, KARNAK

Repair Mastic: Karna-Flex 505 WB, KARNAK

Cleaning Agent: 799 Wash-N-Prep, KARNAK

New Products Added to Roof Coating Line

EPDM Coatings announces the addition of several new products to its roof coating line, including its 97 percent volume solid EnergyMax, Bonding Primers, Rust Inhibitors and Clear-Coat specifically designed for coating skylights, brick and stucco.

EPDM Coatings provides its customers worldwide with a full range of products, including many that have been ASTM tested and CRRC rated, Miami-Dade approved, as well as NSF approved for potable water applications. These diverse additions are designed to allow contractors to pass along those options and savings to their customers.

The company offers solutions for almost all types of roofs, including built-up, modified bitumen, metal, concrete, TPO, EPDM and foam. Also, for roofs on a budget, one base coat of the aromatic polyurethane can fix most leaks, and the application can be completed after a year to get the full benefits of a system. 

For more information, visit www.epdmcoatings.net.

Federal Agency Relies on Silicone Coating System to Protects its Roof

The coating forms a seamless membrane. DLA chose to cover the previous gray coating with a white coating finished with granules to minimize heat absorption. Photos: GE Performance Coatings

The coating forms a seamless membrane. DLA chose to cover the previous gray coating with a white coating finished with granules to minimize heat absorption. Photos: GE Performance Coatings

The cold, snowy winters and hot, wet summers in Scotia, New York, put immense stress on local buildings’ roofs. A damp climate with conditions that often involve standing water can take a toll on conventional roof coatings. That was the reason the federal Defense Logistics Agency (DLA) first chose a waterproof silicone roof coating for its Scotia facility in 1996.

“Most building owners in this area spend thousands, sometimes hundreds of thousands, each year keeping their roofs intact,” says Dave Landry, director of operations for DLA, adding, “After using Enduris by GE, we spend almost nothing in comparison.”

More than two decades later, the coating’s 15-year extended warranty had long run out and DLA was ready to reapply. As in 1996, the alternative to resealing would have been a costly and intrusive tear-off. “We had a terrific first experience with Enduris roof coating,” says Landry. “Twenty-two years later, there was no question about who we’d use.”

Efficient Installation

The GE Performance Coatings team inspected the roof for damage before the work began. After more than two decades of punishing conditions, on average less than five mils of the original 21.5-mil coating surface had worn away. Because silicone coatings are seamless, the roof was also protected from expansion and contraction cycles caused by temperature

More than 20 years after applying a silicone roof coating on the roof of the Defense Logistics Agency in Scotia, New York, PUFF Inc. returned to conduct another installation.

More than 20 years after applying a silicone roof coating on the roof of the Defense Logistics Agency in Scotia, New York, PUFF Inc. returned to conduct another installation. Photos: GE Performance Coatings

fluctuations, which can tear apart dissimilar materials where they overlap. In the end, only 5 percent of the 275,000-square-foot roof required repair—the rest just needed a few more mils of coating. DLA chose to cover the previous gray coating with white coating finished with granules, helping to lower the amount of heat absorbed by the roof and add further protection.

The applicator, PUFF Inc., also experienced the benefits of the silicone coating. “During the seven-week project, we lost only one day to rain,” says Bill Rush, operations manager at PUFF Inc. and an approved applicator for GE Performance Coatings. “If it had been an acrylic coating, we would have likely lost a week to predicted rain delay. Additionally, there were two days that rain came unexpectedly from over the mountains, when the forecast was a 10 percent chance of rain.”

A quicker installation meant savings for the PUFF Inc. team—hotel rooms, per-diem expenses, and the opportunity cost of missing other jobs add up fast. Rush also felt a personal connection to the DLA’s positive experience. “I led the installation 20 years ago,” he says. “It’s a matter of great pride to see how well the system held up.”

TEAM

Roofing Contractor: PUFF Inc., Charlottesville, Virginia, Puffinc.com

MATERIALS

Coating System: Enduris by GE, GE Performance Coatings, GE.com/silicones

SEBS Roof Coating System Designed for Use in Variety of Applications

Mule-HideThe new SEBS Roof Coating System from Mule-Hide Products Co. combines high tensile strength, excellent elasticity, ultra-low moisture permeability and resistance to ponding water, making it an ideal choice for use in a wide variety of challenging roof repair and restoration applications, according to the manufacturer.
 
The solvent-based coating system is designed primarily for use in repairing and restoring metal roofs, but also can be used on TPO, EPDM, asphalt, modified bitumen, Kynar, concrete, Hypalon and PIB roofing systems.
 
The SEBS Roof Coating System includes the following products: SEBS Primer; SEBS Base Coat; SEBS Roof Coating (for use on metal, TPO and Hypalon roofing systems); SEBS+ Roof Coating (for use on metal, TPO, Hypalon, EPDM, asphalt, modified bitumen, Kynar, concrete and PIB roofing systems); SEBS Seam Sealer; and SEBS 1 – Multipurpose Sealant.

The coatings’ solvent base and ultra-low moisture permeability enable them to outperform other coating types in ponding water applications, according to the manufacturer. They will not delaminate if the substrate becomes wet and, unlike water-based coatings, they will not re-emulsify during prolonged exposure to ponding water.

The lack of permeability also helps prevent corrosion of metal substrates and makes the coatings highly resistant to algae and fungi. Antioxidants and light stabilizers ensure the coating system’s durability throughout the roofing system’s service life.

Because the SEBS Roof Coating System is solvent-based, it cannot be shipped to areas that regulate the use of products containing volatile organic compounds (VOCs). 

GE Performance Coatings & Sealants Roof Solutions Will Be Displayed at IRE

International Roofing Expo attendees will find roof solutions and product specialists at GE Performance Coatings & Sealants Booth 340. On display during the March 1-3 event in Las Vegas, the 100 percent silicone GE Enduris roof coating is a solution that provides durability.

“GE Enduris is an answer for roofing protection and restoration,” says Peter Friedli, marketing manager. “For over 50 years, contractors and building owners have trusted us to deliver building products. Our team is looking forward to helping attendees leverage our benefits for themselves.”

GE Performance Coatings experts will be on-site to consult about the components of GE Enduris, provide technical insight, and explore application possibilities.

GE Enduris high solids roof coating stops leaks, improves performance, and extends roof life with a single-coat, primerless application. Able to withstand fluctuating conditions and ponding water, GE Enduris can restore most every type of roof substrate.

For more information on GE Enduris, visit GE Performance Coatings & Sealants’ booth at IRE, or click on this link to visit the website.

RCMA, NSF International Create Roof Coating Materials PCR

The Roof Coatings Manufacturers Association (RCMA) and NSF International have created a product category rule (PCR) for roof coating materials. PCRs enable product environmental information to be more transparent and useful to the marketplace. Products covered in this PCR include fluid-applied and adhered coatings used for roof maintenance or roof repair, or as a component of a roof covering system or roof assembly. 
 
Based on international environmental management guidelines (ISO 14025), a PCR defines how to conduct a life cycle assessment for a particular product group and what to include in the resulting report. A life-cycle assessment measures inputs, outputs and environmental impacts of a product across its lifespan. The environmental product declaration (EPD) is the third-party-verified report that explains the data generated from a life cycle assessment. What is included in the EPD is also defined by the PCR.

The NSF International National Center for Sustainability Standards (NCSS) utilized an open consultative process to develop the PCR with participation from an expert panel of RCMA members, suppliers, regulatory agencies, environmental organizations and end users.  RCMA promotes the benefits of roof coatings and represents manufacturers of asphaltic and solar reflective roof coatings as well as suppliers to the roof coatings industry. 

“This product category rule developed by RCMA and NSF International provides our industry a needed guideline for calculating and reporting the environmental attributes of roof coatings,” says Jim Kirby, executive director of RCMA. “The subsequent life cycle analyses developed by our members using the PCR can provide a basis for improvement to enable reductions in environmental impacts over time. We look forward to the positive impact this will have on the industry and those seeking more sustainable building products.”

“As a manufacturer participating in the PCR development, we support our industry in providing transparent and science-based information to our customers,” says Douglas P. Mazeffa, environmental project manager at Sherwin Williams. “Our company is committed to helping customers make informed, environmentally-based purchasing decisions.”
 
“Industries benefit from NSF International’s standards development process that was used to develop the PCR for roof coating materials,” states Jessica Slomka, manager of the NSF International National Center for Sustainability Standards. “By engaging RCMA members and other stakeholders, we help ensure the environmental impacts in the life cycle of a product are represented. The result is a defined set of rules that enable comparative data to be gathered and reported in a standardized fashion. This is crucial in helping builder’s source products that meet their environmental goals.”

Verified environmental product declarations (EPDs) as defined by this PCR may help building projects qualify for points through the LEED v4 Material and Resource credits and comply with the International Green Construction Code (IgCC).