The Exxon Lubricants Plant is located in Paulsboro NJ within a 30-minute drive from Philadelphia. This plant manufactures, packages, warehouses, and distributes commercial, marine, and industrial lubricants. The large facility features interconnected metal roofs covering several hundred thousand square feet.
The Challenge
The metal roofs of the sprawling industrial complex were initially constructed using a specialized galvanized steel alloy known as galvalume. This unique commercial roofing system is engineered to provide superior corrosion resistance and longevity in comparison to traditional galvanized steel roofing. However, as time passed, the relentless exposure to the elements began to take its toll. Subtle signs of corrosion were now starting to appear on the metal panels, with rust spots and discoloration gradually appearing.
Numerous leaks had also begun springing up in the roof, including some that threatened major equipment in the plant. Unfortunately, many unsuccessful roof repair attempts had been made using silicone-based roof coatings. These silicone coatings, while initially seeming like a quick and easy fix, proved to be more trouble than they were worth in the long run. Silicone patches are not compatible with acrylic coatings and this necessitated their removal or special treatment.
The Acrymax Solution
The metal roof coating system provided by Acrymax was essential for restoring the durability of the Exxon Lubricants Plant’s roofing. After a comprehensive inspection and assessment of the conditions on the roof, Acrymax’s team carefully evaluated the situation and determined that the optimal solution would be a spray application of the Acrymax ARS-2-30XT system. The system produces a dry film thickness of 30 mils. This specialized commercial roofing system was selected in part because Exxon required a 20-year warranty on the project to ensure a long-term solution.
The ARS-2-30XT system provides exceptional waterproofing, UV resistance, and durability – all key factors that were essential given the specific challenges of this particular roofing project. The spray application process allowed for a smooth, uniform coverage that conforms perfectly to the roof’s contours, creating a robust, monolithic barrier against the elements. This application method also minimizes the risk of leaks or weak points, providing the utmost reliability and peace of mind to the client. Furthermore, the ARS-2-30XT formulation is very flexible and able to accommodate natural building movements and shifts, providing long-lasting protection without cracking or peeling. After a thorough assessment and with careful attention paid to warranty requirements, Acrymax’s premium ARS-2-30XT system provided a durable roofing solution that will protect the building and meet the customer’s needs for years to come.
A unique aspect of this particular solution was the utilization of Acrymax PC-535 as the basecoat for the entire system. This innovative elastomeric coating stands out from traditional options due to its direct-to-metal and self-priming capabilities, which eliminate the need for a standard primer in most metal roof coating situations. Rather than requiring a 4-coat system, this elastomeric rust inhibitive coating allows the entire solution to be applied in just 3 coats, resulting in significant cost savings during the application process. This innovative elastomeric coating technology is a key differentiator that makes this solution stand out, offering applicators an efficient, cost-effective alternative to traditional multi-coat systems that typically involve the use of a separate primer layer.
The Result
The client’s phased installation plan has progressed as expected, with the successful completion of the initial Phase 1 in 2023 and the subsequent Phase 2 in 2024. Building upon these solid foundations, the client now looks ahead to finishing the balance of the roofs in the coming years. Acrymax’s roof coating services have provided Exxon with a durable, cost-effective solution that extends the lifespan of its facilities, reinforcing the reliability and value of a long-term partnership.