A high-quality, multi-layer manufacturer of decorative design products was experiencing widespread roof leaks across its 261,000 sq. ft. manufacturing facility. The building contained two existing roofing systems, with the most recent retrofit consisting of a 19-year-old TPO membrane nearing the end of its service life.
Facility leadership was preparing for a full roof replacement, which would have required removing both roofing systems down to the structural deck. Complicating matters further, the facility operated 24/7, meaning any roof replacement would require extensive interior protection and pose significant risk to ongoing printing and manufacturing processes.
Before moving forward with replacement, Clevercoat’s proactive asset management approach prompted a deeper evaluation to determine why and where water intrusion was occurring throughout the building.
Rather than replacing the entire roof system, Clevercoat implemented a targeted restoration strategy.
The damaged insulation and membrane—less than 4,000 sq. ft.—were removed in the five affected areas. Ponding conditions were corrected using new tapered insulation, restoring proper drainage.
Once repairs were complete, the entire roof and flashing system was restored using a liquid-applied, seamless 60-mil roofing system. This system fully integrated with the existing 60-mil membrane, creating a new 120-mil seamless roof assembly and qualifying the facility for a 20-year Total System Preventative Maintenance Warranty.
This solution eliminated the need for interior protection, avoided any disruption to 24/7 manufacturing operations, and preserved both existing roofing systems.
By avoiding a full tear-off, approximately 858 tons of roofing material were kept out of landfills—significantly reducing environmental impact and supporting the facility’s long-term sustainability goals.
By selecting a strategic restoration approach instead of full replacement, the facility avoided $4,940,000 in combined costs associated with roof replacement, interior protection, and operational disruption—while receiving a higher-quality, longer-lasting roofing system.
