Virginia Class A Licensed and Insured Roofer

Cool Roof Coating Energy Savings
Operation Smile World HQ

Written By William W. Warwick IV - RCI Certified Cool Roof Industry Expert
LEED Silver Building Reduces Annual Energy use 30% 

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lternatively, when you select a text box a settings menu will appear. Selecting ‘Edit Text’ from this menu will also allow you to edit the text within this text bo. 
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Contractor Warwick Builders LLC
Contractor Email william.warwickroofing@gmail.com
Category Elastomeric Roof Coatings
Installers Warwick Builders LLC
Project Operation Smile World HQ
Location Virginia Beach, Virginia
Type of Job Elastomeric Solvent Free Silicone over 3 yr old TPO
Square Footage of Job 47,000
Equipment Used Super Spreader Rollers and Graco X-70 Pumping the material to the roof into the hoppers.
Number of People Needed For The Job 7
Number of days required by the Job 45
Foam and coatings used GACO Flashfoam was used around perimeter of the to seal the building envelope gaps and provide additional Building envelope thermal and air insulation.
Material Supplier GACO-Western Supplied S-2000 coating and FlashFoam
Project Description
The building itself was built to a LEED Silver standard in 2013.

When we were approached to help them find solutions, the building was already 3 Years old and built to a World Class standard, with a Facility housing a distribution and supply hub, a greeting area with tall glass atrium and the rest being comprised of world class meeting, office, and other spaces.

3/4 of the building was office space, 1/4 was industrial warehouse storage for sensitive medical equipment which was being readied for shipment all around the world.

We applied the Solvent Free Silicone Coatings and Flash Spray Foam to all the gaps and crevices, overhangs, penetrations and roof and exhaust vents hoods, HVAC cowlings, and other areas where interior conditioned air could leak or escape and allow exterior air into the building envelope on the roof side, we sealed it and coated it to stop water and air infiltration.
Innovation
The most innovative thing about this project is that it was the first time in our career (20 years in coatings) that a company with a 3 year old building built to such a high LEED Silver and world class standards, wanted to coat the 3 year old TPO roof with a coating strictly to reduce energy usage.

Prior to this application of Roof Coatings, the coatings market was pretty much limited to coating existing roofs that reached the end of their useful life or had so many leaks that the owners just wanted the leaks to stop. Either way - we had never been asked to coat a roof that was less than 7 years old before, let alone to coat a roof on a building that was already pretty energy efficient with an existing LEED Silver Certification.

If the owners were going to realize a good ROI - I proposed to them that we needed to spend a little extra and seal all the penetrations and seams and gaps and cracks in the roof system - because if we don't do that - then air leaks may mitigate the energy benefits of the cool roof systems.
Best Practices
The roof system and warranty was for a 20/20 NDL warranty and a pull adhesion test and destructive samples were taken of the TPO for lab analysis by GACO and approved for coatings, as most Single Ply roofs need at least 3 years to age to be coated.

We scanned the entire roof with infrared and found no issues, and then we proceeded to install our safety, fall protection, and other systems to safely do the project.

The Roof was inspected by GACO western technical services and final inspection was done by taking samples and field analyzing for Mils thickness with a optical comparator to pass minimum 38 mils requirement for a 20/20 NDL warranty.
Problem Solving
The most difficult part of this roof project was that we could only access the roof from one small location, there could be no major disruption of work or parking etc. We used up about 6 spaces and fenced off our area to prevent kids from getting there.

We had to carry every bucket of material up a lift, 150ft to one level, carry up a ladder to another level, to another level to another level - there were 5 roof sections, each one higher than the other and accessible only from a built in roof ladder.

We had to work together as a team - if you were workin on end of the building and needed a brush it would take you about 18 minutes to get it...

It was not the biggest roof, the tallest nor any of those other things, but it was one of the most time consuming ones to do - just because it was so cut up and we had to work from one tiny 20 ft wide access spot.
Risk Mitigation
We did full safety meetings daily on power equipment and fall protection, PPOE, etc, and also used Manlift to convey men and materials to the roof in place of ladders to prevent injury, since the heights were over 24ft to the roof.

We had fire extinguishers places all around the roof and ground area, clearly marked for fuel storage and chemical storage. We had fire safety blankets and other fire safety devices within 25ft of all gas powered equipment.

42 inch OSHA approved 30lbs roof warning perimeter and lines were used to create safe work spaces and when leading edge work was done, the workers were attached to mobile fall anchors that used counter weights to prevent falls.

Workers had full helmet with chin strap protection, as well as safety Vests with ANSI and osha reflection.

We also had a former Army Medic on staff with a complete combat and triage emergency kit, for any injuries that may occur and we also had a fall rescue winch system in case a worker fell over the edge to retrieve them.

We also installed two roof hatch guardrail systems which meet the OSHA regulations for opening and roof hatches and fall protection to bring the building and roof up to current OSHA standards.

In addition we also used Fire-rated intumescent foam in any area that was a penetration, adding both fire and air and water sealant to the building envelope.
Value for Money
This project was done for about 155,000 or a little over $3.00 a sqft. The Reduction in energy usage is around $32,000 per year. The Roof coating is estimated to pay for itself within 5.8 years. HVAC maintenance costs are lower as well.

The roof was hit by a small tornado in spring 2017 - there were zero reported leaks. The roof warranty is backed with a 20/20 NDL warranty that covers all defects.

Its the only roof system that pays for itself in less than 10 years.
Speed of Delivery
Due to the cut up nature of the roof, it definitely took longer to complete than a 47k sqft roof that was flat, but we still completed all work in less than 65 days, in the middle of hurricane season.
Environmental Sustainability
The Spray foam we used was instrumental in sealing and providing a good thermal beak in all the penetrations gaps, seams, and other cracks and odd areas where a coating would simply drip through or out. I can say with absolute certainty that the key to getting maximum performance from any roof system is sealing all the penetrations, and this roof had hundreds of sqft of penetrations to leak air and water into. We could not have achieved the overall energy reduction without the combination of Sealing with foam and coating with the coatings, it a one two punch and one requires the other to work the most efficiently.

Other than the foam - the coatings we applied are Title 24 - solvent free, energy star approved GACO S2000 - with the GACO E5320 Water based epoxy primer, and also GACO Wash for cleaning the roof prior to application.

The only waste we produced was:

1. dirty water from pressure washing the roof, which was cleaned and recycled through a water filter being put back into the garden on site,
2. A dozen 55 gal steel drums and a few hundred 5 gallon plastic pails.

All of which was non-toxic and 100% recyclable.

From a green and C2C and environmental standpoint, there is no greener or more sustainable method of Roof Renovation and protection.

Moreover the thickness, durability, and effectiveness of the original TPO roof under the coatings is preserved in its near original condition, so there is no loss of value or performance.

Theoretically the top coating of Silicones could fail or allow to fail over the course of 20 to 25 years, and you still have a TPO roof under it - that could last another 15 to 20 years on it own.
About the Contractor
We are a Roofing and Building company that is dedicated to providing the best practices and best solutions for our clients, with full line of roof services ranging from roof inspections to complete tear off and replacements. We focus on saving roofs and rehabilitating them with cool roof coatings because that is most often the best value for our clients and when coating the roof is no longer a viable option then we give them bids for the next best solutions which is usually a Cool Roof approved White Single ply membrane or a SPF application with a Silicone Coating over it for best performance and value.
Warwick Roofing - Virginia Beach, Norfolk, Portsmouth, Suffolk, Chesapeake