The Challenge

The large commercial complex in Mahwah, NJ includes an office building and warehouse totaling approximately 400,000 square feet of roof area. These buildings were covered with a mechanically attached Chlorinated Polyethylene (CPE) membrane. While the membrane was holding up reasonably well, it was no longer covered under warranty. A complete roof replacement would be prohibitively expensive and disruptive to operations, which led the client to search for a less expensive, less disruptive option that could extend the life of the existing roof system.

The Acrymax Solution

To meet the needs of this project, Acrymax proposed the use of the Acrymax ARS-1-SP system. This system is a fluid-applied elastomeric reinforced composite roof system. It uses the existing roof membrane as the substrate and “recycles” it – incorporating the existing roof membrane into the new system, creating a composite system that is stronger and longer-lasting than the original.

Preparation for installation of the Acrymax system included a thorough power wash at high pressure. Once preparation was complete, the ARS-1-SP was applied directly to the prepared surface. The system is a 3-step process. The first step is to apply the AF-130BC basecoat while simultaneously embedding Poly-1 Reinforcement into the wet coating. Step 2 was the application of an intermediate coat of AF-130. Finally, a finish coat of AF-130 was applied. Each coat was a different color to ensure complete and uniform coverage. The new fluid applied membrane is 45 mils and when combined with the existing membrane resulted in a composite membrane of approximately 100 mils of double protection.

The beauty of this approach lies in its ability to extend the life of the roof while minimizing waste and remaining affordable, making it a sustainable choice for building owners.

The Results

The results of this project were impressive. By combining the original roof membranes with Acrymax’s advanced elastomeric roof coatings, the client received a robust, watertight surface that greatly enhanced the roof’s performance. This recycling approach didn’t just save the client money; the phased approach also kept the disruption to a minimum. The ongoing operations of the office and warehouse were able to continue throughout the application process. With over 20 years of exposure, this roof is still providing leakproof protection. The decision to recover rather than replace the roof balanced current roofing and financial needs with long-term sustainability.