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The challenge
An aging corrugated metal roof in St. Augustine with heavy oxidation, leaks at fasteners and seams, and severely UV-degraded acrylic skylights was restored rather than replaced.
The roof showed heavy oxidation (rust), minor leaks at fastener points and seams, and severely UV-degraded acrylic skylights. The owner needed to stop the leaks, gain immediate energy efficiency, and restore the light-transmitting skylights without paying for a full roof and skylight replacement.
The work, in three phases
Surface preparation. The entire roof was pressure washed to remove dirt, chalking and loose contaminants, and areas of heavy corrosion were spot-treated with a rust-inhibiting primer to ensure adhesion.
Sealing. All fastener heads, seams and roof penetrations were sealed with the recommended Gaco patching compound or tape, reinforcing the critical areas against water intrusion.
Skylight restoration. A durable, highly UV-resistant clear Gaco acrylic resin coating was applied to the acrylic domes, restoring their integrity and clarity and improving interior light transmission.
The result
The highly reflective white finish coat substantially reduced the roof's temperature, producing verifiable energy savings. Preserving the existing roof structure also diverted tons of metal and plastic waste from the local landfill.