GacoFlex Acrylic System and Skylight Restoration in St. Augustine, FL
The Challenge: An aging corrugated metal roof in St. Augustine was exhibiting signs of heavy oxidation (rust), minor leaks at fastener points and seams, and severely UV-degraded acrylic skylights. The owner needed a solution that would stop leaks, provide immediate energy efficiency, and restore the integrity of the light-transmitting skylights without incurring the high cost of a full roof and skylight replacement.
The Solution: Installation of a comprehensive GacoFlex Acrylic Roof Coating System, specifically chosen for its durability and high-reflectivity properties on metal, coupled with a specialized acrylic resin treatment for the existing skylights.
Project Scope
Corrugated metal roofs present unique challenges due to their increased surface area and numerous fasteners.
The Solution: GacoFlex Acrylic Roof System
Phase 1: Surface Preparation The entire roof surface was pressure washed to remove dirt, chalking, and loose contaminants. Areas of heavy corrosion were spot-treated with a rust-inhibiting primer to ensure optimal adhesion of the coating system.
Phase 2: Seam, Penetration, and Fastener Treatment Prior to the main application, all fastener heads, seams, and roof penetrations (pipes, vents) were meticulously sealed using the recommended Gaco patching compound or tape, reinforcing these critical areas against water intrusion.
Phase 3: Skylight Restoration with Acrylic Resin Coating The existing acrylic dome skylights, which had become yellowed and brittle from UV exposure, were prepped. A durable, highly UV-resistant, clear Gaco acrylic resin coating was expertly applied. This coating restored the integrity and clarity of the acrylic domes, providing a renewed barrier against the elements and improving interior light transmission, eliminating the need for costly skylight replacement.
Phase 4: GacoFlex Acrylic Base and Finish Coats The main roof area was then fully coated:
Results & Benefits
The Challenge: An aging corrugated metal roof in St. Augustine was exhibiting signs of heavy oxidation (rust), minor leaks at fastener points and seams, and severely UV-degraded acrylic skylights. The owner needed a solution that would stop leaks, provide immediate energy efficiency, and restore the integrity of the light-transmitting skylights without incurring the high cost of a full roof and skylight replacement.
The Solution: Installation of a comprehensive GacoFlex Acrylic Roof Coating System, specifically chosen for its durability and high-reflectivity properties on metal, coupled with a specialized acrylic resin treatment for the existing skylights.
Project Scope
Corrugated metal roofs present unique challenges due to their increased surface area and numerous fasteners.
- Substrate Condition: Moderate rust, sound structure, and two existing acrylic dome skylights.
The Solution: GacoFlex Acrylic Roof System
Phase 1: Surface Preparation The entire roof surface was pressure washed to remove dirt, chalking, and loose contaminants. Areas of heavy corrosion were spot-treated with a rust-inhibiting primer to ensure optimal adhesion of the coating system.
Phase 2: Seam, Penetration, and Fastener Treatment Prior to the main application, all fastener heads, seams, and roof penetrations (pipes, vents) were meticulously sealed using the recommended Gaco patching compound or tape, reinforcing these critical areas against water intrusion.
Phase 3: Skylight Restoration with Acrylic Resin Coating The existing acrylic dome skylights, which had become yellowed and brittle from UV exposure, were prepped. A durable, highly UV-resistant, clear Gaco acrylic resin coating was expertly applied. This coating restored the integrity and clarity of the acrylic domes, providing a renewed barrier against the elements and improving interior light transmission, eliminating the need for costly skylight replacement.
Phase 4: GacoFlex Acrylic Base and Finish Coats The main roof area was then fully coated:
- Base Coat: A uniform layer of GacoFlex Acrylic Base Coat was applied to ensure complete encapsulation of the metal and primer.
- Finish Coat: Two subsequent coats of GacoFlex White Acrylic Finish Coat were applied. This final layer provides superior solar reflectivity, drastically reducing the roof temperature and lowering the building's internal cooling costs.
Results & Benefits
- Total Waterproofing: The system completely sealed all fastener points and seams, halting all previous leaks and creating a monolithic, seamless membrane over the entire metal surface.
- Skylight Integrity: The acrylic resin coating successfully restored the skylights, extending their service life and delaying future replacement, all while significantly improving the quality of natural light entering the facility.
- Cost Savings: The restorative coating cost was a small fraction of the estimated expense for a full metal roof and skylight tear-off and replacement.
- Energy Efficiency: The highly reflective white finish coat substantially reduced the roof's temperature, leading to verifiable energy savings and a more comfortable interior environment.
- Sustainability: By preserving the existing roof structure, the project diverted tons of metal and plastics waste from the local landfill.
