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Case Studies – Roofing

Acrymax systems have been used for restoration and recovery of many different types of roofs. Following are just a few of the many successful applications where Acrymax has provided solutions.

Click here to see Metal Roof Coating Systems

Click here to see Single-Ply Roof Restoration Systems

Click here to see Asphalt Roof Restoration Systems

 

Metal Roof Coating Systems

MAT Building

United States Coast Guard

Bayonne, NJ

ARS-2-PVDF

MAT building1   MAT building2

 

   

The metal roof at the USCG Station in Bayonne, New Jersey had been leaking for years. Additionally, the color of the metal panels that had been installed was not consistent with the red color scheme associated with the Coast Guard.  Since the Coast Guard had successfully used Acrymax on other roofing projects they contacted Acrymax for a solution. Adding another dimension to the project was the fact that the existing roof was coated with a factory applied fluoropolymer finish and these types of finishes can be difficult to adhere to. Fortunately, Acrymax had the answer. Acrymax AF-5500 is a high performance coating that is based on new waterborne fluoropolymer resins that are state-of-the art.  This coating exhibits superior weatherability and color retention and important for this project has good adhesion to metal roofs with fluoropolymer finishes. Acrymax worked closely with the design team from the Coast Guard to develop the specification that called for applying a primer coat of AF-5500 in a gray color, followed by reinforcement of the seams with AF-130 Elastomeric Acrylic coating, and finally a 2 coat application of AF-5500 in Coast Guard Red.  The roof was completed in the summer of 2010.

 

Port Newark-Elizabeth Marine Terminal

Port Authority of New York & New Jersey

Newark, NJ

ARS-2M

MAT building1   MAT building2

 

   

The Port Newark-Elizabeth Marine Terminal is one of the busiest ports in the world. It is the largest container port in the eastern United States and the third largest in the country. In addition to container operations there are many large warehouse buildings at the Port that were built in the 1950’s. The roofs of these buildings consist of aluminum corrugated panels.  Through years of exposure to extreme heat and biting cold and the constant expansion and contraction caused by these temperature fluctuations the roofs had developed extensive leaks. To solve the problem the Port Authority wrote a specification for coating these roofs with an elastomeric acrylic coating system.  Acrymax and one of our approved applicators won the first project in a competitive bidding process. The specification called for reinforcing all the panel seams and then spray applying a 30 mil elastomeric coating over the entire roof. This project was a resounding success and the Port put the next project out for bid.  Unfortunately, competitive bidding lead to a problem. To reduce costs and win in the competitive bid process the manufacturer of a different coating system that was used on the second project did not require reinforcing the seams and used a “seam sealer” instead. Unfortunately, this method was not appropriate for these types of roofs and after completion they continued to experience leaks.  Ultimately, the solution was to go back and reinforce the seams on this roof. At this point Acrymax approached the Port Authority with a proposal that would save money and still give them the leak-free performance they needed. The original specification written by the Port called for 30 mils of coating on the roof panels and 45 mils on the seam areas.  Acrymax proposed substituting a high-strength elastomeric coating as a finish coat instead of the standard elastomeric coating that was in the original spec. This would allow for reducing the dry film thickness of the coating system on the panels to 20 mils from the originally specified 30 mils. Less material would be required and the costs of the applied system would be reduced. The Port Authority liked what they heard and based on their prior experience with Acrymax decided to rewrite the specification for the roofs. To insure compliance with the specification it was clearly stated that no substitutions for the Acrymax coatings would be allowed. Since that time over 1,000,000 square feet of roofs at Port Elizabeth were successfully completed with the Acrymax system.

 

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Single-Ply Roof Restoration

Sharp Electronics

Mahwah, NJ

ARS-1SP

MAT building1   MAT building2

 

   

This project included an office building and a warehouse totaling approximately  400,000 square feet. The roofs were covered with a mechanically attached CPE (Chlorinated Polyethylene) membrane that was in generally good condition, but they were out of warranty. Roof removal and replacement would be prohibitively expensive and extremely disruptive, so Acrymax proposed a system that could be used to extend the life of existing roof membranes. The ARS-1SP system is a fully reinforced fluid applied roof system that “recycles” the existing membrane into a new system. The ARS-1SP system was applied directly to the properly prepared CPE membrane where it adheres directly to the existing membrane to create a composite system. The resulting membrane combines the two systems into one and provides 2 layers of high strength reinforced waterproof protection.

 

Pittston High School

Pittston, PA

ARS-1SP-50XT

MAT building1   MAT building2

 

   

In 1997 the Pittston High School was being extensively renovated and the roof needed to be addressed. After researching Acrymax the roof consultant on the project decided to specify an Acrymax system. One of the requirements for the roof project was a 15-year labor and material warranty. The system specified was a fully reinforced system that included reinforcement installed in AF-130BC followed by 3 coats of AF-130XT high-strength elastomeric coating.  Compared to the costs of removal and replacement the ARS-1SP-50XT saved the school district hundreds of thousands of dollars that could be redirected to the educational needs of the students.

 

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Asphalt Roof Restoration

Helfferich Gym

Ursinus College

Collegeville, PA

ARS-1A

MAT building1   MAT building2

 

   

This roofing project was begun in the mid 1980’s. The smooth surfaced asphalt roof had begun to experience leaks and showed significant signs of deterioration, but the money for a complete roofing project was not available. Acrymax suggested a roof restoration project that could be phased in over a few years. The first year the front third of the roof was completed while at the same time repairs were made to the balance of the roof to stop the leaks that were occurring. Over the next 2 roofing seasons the balance of the project was completed.  Since completion the roof has received periodic maintenance coatings and now after over 25 years of service this roof is still in excellent condition. It is expected that with regular maintenance and periodic recoats that the life of this roof can be extended indefinitely.

 

Acrymax schedules periodic tours of this roof to display the impressive performance of the reinforced elastomeric membrane system used. If interested in our next tour please contact Acrymax.

 

Coolest Block

Philadelphia, PA

ARS-3

MAT building2 MAT building1  

 

   

Philadelphia has taken a leadership role in promoting cool roof coatings to mitigate the urban heat island effect as evidenced by legislation recently signed by Philadelphia Mayor Michael Nutter. With the goal of helping Philadelphia become “the Greenest City in America” the new law requires installation of energy-efficient reflective roofs or green roofs on low slope roofs in the city. To help promote the “greening” of Philadelphia, the City of Philadelphia, The Energy Coordinating Agency, Dow Chemical, and Greenworks Philadelphia came together to form Retrofit Philly and to sponsor the “Coolest Block in Philadelphia” contest.   In the summer of 2010, following a competition among approximately 100 communities, the 1200 block of Wolf Street was selected to become the “Coolest”. As the winner of the contest, Wolf Street received a host of home energy improvements. Reflective roof coatings to provide cool roofs to the entire block were a key part of those energy improvements. Sponsors of this very “Cool” program include the City of Philadelphia, the DOW Chemical Company, Greenworks Philadelphia, and the Energy Coordinating Agency.  Acrymax was selected to supply the cool roof coatings. Additional information about the Acrymax coatings used on this project can be found at http://www.retrofitphilly.com/faq/index.htm#1200

 

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