System Overview
Roof restoration coatings offer a cost-effective alternative to complete roof replacement by applying liquid-applied elastomeric membranes over existing roofs. These systems seal leaks, reflect UV radiation, improve energy efficiency, and extend roof life by 10-20+ years at a fraction of replacement cost.
Restoration coating systems can be applied to metal, single-ply, modified bitumen, BUR, spray foam, and concrete roofs. The coating creates a seamless, monolithic membrane that protects the existing roof from weathering and UV damage. As an estimator, understanding substrate compatibility, preparation requirements, and coating selection is essential for accurate pricing and system performance.
Pro Tip: Roof restoration is only viable on structurally sound roofs with minimal defects. Buildings with saturated insulation, failed deck, or extensive damage require replacement, not coating. Always conduct thorough roof assessment before proposing restoration.
Coating Types
Silicone Roof Coatings
Premium restoration coating with exceptional UV resistance, ponding water tolerance, and longest service life. Silicone coatings do not require primer on most substrates and maintain flexibility over decades. Most popular choice for commercial roof restoration.
20-30+ years (with periodic top-coating)
20-40 mils (2-3 coats typical)
$50-80 per gallon
0.8-1.5 gallons per 100 SF (per coat)
Metal, SPF, EPDM, mod-bit, BUR, concrete
$2.50-4.50/SF (complete system)
- • Superior ponding water resistance (can withstand weeks of standing water)
- • Excellent UV stability - minimal chalking or degradation
- • No primer required on most substrates (cost/time savings)
- • Maintains flexibility at temperature extremes (-40°F to +180°F)
- • Easy to recoat - silicone bonds to silicone
- • Highest reflectivity retention over time
Acrylic Roof Coatings
Traditional restoration coating with good UV resistance and bright white finish. Lower cost than silicone but requires excellent drainage and cannot tolerate ponding water. Popular for metal roof restoration and well-drained low-slope roofs.
10-15 years (proper drainage required)
20-30 mils (2-3 coats)
$30-55 per gallon
1.0-1.5 gallons per 100 SF (per coat)
Metal, mod-bit, BUR, concrete (primer required)
$1.80-3.50/SF (complete system)
- • Cannot withstand ponding water (degrades in standing water)
- • Requires primer on most substrates (adds cost/time)
- • Shorter lifespan than silicone
- • More maintenance intensive
- • Not suitable for flat roofs with drainage issues
Polyurethane & Polyurea Coatings
High-performance coatings with excellent durability, abrasion resistance, and chemical resistance. Often used as base coat under silicone or acrylic top coat. More expensive but provides superior protection in demanding environments.
15-25 years
30-50 mils
$60-100+ per gallon
Spray, roll, or brush
Best For: High-traffic roofs, chemical exposure environments, or as premium base coat in multi-layer systems. Often paired with silicone top coat for maximum performance.
Asphalt Emulsion & Aluminum Coatings
Traditional asphalt-based coatings for BUR and modified bitumen roofs. Lower performance than modern elastomerics but economical for short-term protection. Aluminum pigments provide reflectivity.
3-7 years
$15-35 per gallon
$0.80-1.80/SF
Temporary protection, budget projects
Not Recommended: For long-term roof restoration or warranty-backed systems. Modern elastomeric coatings provide far superior performance and lifecycle value.
Substrate Compatibility
Success of a restoration coating system depends on proper substrate compatibility and preparation. Not all coatings work on all substrates.
| Substrate Type | Silicone | Acrylic | Polyurethane | Special Notes |
|---|---|---|---|---|
| Metal (all types) | Excellent | Excellent | Excellent | Clean, remove rust, prime if needed |
| SPF (spray foam) | Excellent | Good | Excellent | No primer needed (silicone) |
| EPDM (rubber) | Excellent | Fair | Good | Clean thoroughly, primer critical |
| TPO/PVC | Fair | Fair | Fair | Difficult adhesion, primer essential |
| Modified Bitumen | Excellent | Good | Excellent | Granule surface ideal for coating |
| BUR (smooth) | Excellent | Good | Excellent | Prime if surface is weathered |
| BUR (gravel) | Poor | Poor | Poor | Remove gravel first (costly) |
| Concrete | Good | Good | Excellent | Primer required, crack repair critical |
System Components
1. Roof Cleaning & Preparation
Critical first step. Coating adhesion depends on clean, sound substrate. Dirt, oils, loose material, and biological growth must be removed.
2. Repairs & Substrate Preparation
All defects must be repaired before coating. Seams, penetrations, fasteners, and damaged areas require attention.
3. Primer (If Required)
Improves coating adhesion to difficult substrates. Required for acrylic systems and some substrate types.
4. Base Coat
First coating layer provides primary waterproofing and builds mil thickness. Applied at higher coverage rate for better penetration.
5. Reinforcing Fabric (Critical Areas)
Polyester or fiberglass mesh embedded in coating at seams, penetrations, transitions, and stress points. Provides strength and crack-bridging.
6. Top Coat(s)
Final layer(s) provide UV protection, color, and achieve target dry film thickness. One or two top coats depending on warranty requirement.
7. Granules or Surfacing (Optional)
Embedded granules enhance durability, provide slip resistance, and improve hail resistance. Common in high-traffic areas or hail zones.
Estimation Considerations
Roof Assessment Required
Physical roof inspection is mandatory before bidding coating work. Cannot accurately estimate repairs without seeing condition.
Warranty Requirements
Manufacturer warranties specify minimum dry mil thickness, preparation standards, and application methods. Must follow exactly.
Access & Logistics
Material handling for coating projects is labor-intensive. Buckets must be carried to roof, requiring significant manpower.
Weather & Scheduling
Coating application requires dry conditions and proper temperature. Rain within 24 hours of application can ruin coating.
Material Takeoff Details
Step-by-Step Takeoff Process
Measure entire roof surface. Coating systems cover all roof area including flashings and details.
Based on substrate, warranty requirement, and budget. Typical system: base coat + reinforcement + 1-2 top coats.
Convert area and target thickness to gallons needed. Account for surface porosity and waste.
Measure all seams, penetrations, walls, and transitions requiring fabric reinforcement.
Based on roof inspection findings. Budget allowance if inspection not yet complete.
Calculate primer coverage for substrate type. May not be needed for silicone on some substrates.
Spray equipment, rollers, brushes, tape, drop cloths, safety equipment.
Critical: Coverage rates vary significantly based on substrate porosity, texture, and condition. Porous or aged substrates absorb more coating. Always verify manufacturer coverage rates for specific substrate and add 10-15% waste factor.
Labor Estimation Guidance
Coating application is labor-intensive. Preparation work (cleaning, repairs) often takes longer than coating application itself. Crew size typically 3-5 workers depending on project size.
Baseline Productivity Rates
| Task | Hours/Square | Crew | Notes |
|---|---|---|---|
| Roof cleaning/power wash | 0.4-0.8 | 3-4 | Heavily soiled roofs take longer |
| Repair work (seams/flashings) | Variable | 2-3 | Depends on condition, $5-15/LF |
| Primer application | 0.3-0.5 | 2-3 | Spray or roll |
| Fabric reinforcement install | 2.0-3.5 | 2 | Detail work, labor intensive |
| Base coat (spray) | 0.8-1.5 | 3-4 | Fastest method |
| Base coat (roll/brush) | 1.2-2.0 | 3-4 | Better mil build, slower |
| Top coat (spray) | 0.6-1.2 | 3-4 | 24-48 hr cure before top coat |
| Top coat (roll/brush) | 1.0-1.8 | 3-4 | Finish quality better |
| Detail work & cleanup | 0.3-0.6 | 2-3 | Final inspection, touch-ups |
Example Labor Calculation
Key Takeaways
- ✓Roof restoration extends life 10-20 years at 40-80% cost of replacement
- ✓Silicone coatings offer best performance and longest life - premium choice for most applications
- ✓Roof inspection is mandatory before estimating - cannot price repairs without seeing condition
- ✓Preparation work (cleaning, repairs) often equals or exceeds coating application time
- ✓Warranty requirements dictate minimum dry mil thickness - must meet or exceed to qualify
Get the Complete Roof Coating Estimating Template
Excel template with coating quantity calculators, mil thickness converters, substrate compatibility charts, repair allowance worksheets, labor estimators by application method, and warranty requirement checklists.
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