Project Snapshot

Facility: Rudy’s Furniture (Asheville, NC)
Roof Type: Built-Up Roofing (BUR), low-slope
Approximate Roof Area: 22,000 square feet

Introduction

When a commercial roof begins to show its age, facility managers are often forced into a difficult decision: continue paying for recurring repairs while accepting increased interior risk, or move forward with a full roof replacement that may be disruptive, expensive, and premature.

For many buildings, there is a practical middle path —commercial roof restoration— when the existing system is still structurally serviceable and moisture conditions allow.

This case study documents how a silicone roof coating restoration was used to stabilize an aging BUR system, correct recurring failure points, and extend the roof’s usable life without an immediate tear-off. It is a representative example of when coating restoration can function as a risk-reduction strategy for aging but serviceable low-slope commercial roofs.

The Challenge

A serviceable roof becoming increasingly risky

The building’s existing BUR roof had a history of repairs and was trending toward eventual replacement. The goal of this project was not to mask underlying problems, but to stabilize the system, correct persistent weak points, and provide a durable protective surface that reduced risk for ownership.

The solution needed to:

• Reduce recurring leak pathways, especially at details
• Delay full replacement without compromising performance
• Create a cleaner, more predictable maintenance path

The Restoration Process

Roof coatings succeed or fail based on preparation and detail work —not on the coating alone. On aging low-slope systems, most failures occur at transitions and penetrations rather than across the open field.

This restoration followed a simple guiding principle:

Reinforce and prepare the details first. Then protect the entire field.

The scope combined cleaning, targeted repairs, reinforcement, and a specified silicone system designed to create a continuous protective membrane.

Preparation & Readiness

• Work planning for staging, roof access, safety, and operational coordination
• Targeted cleaning to remove contaminants that reduce adhesion
• Rust-inhibiting primer applied where corrosion was present

Detail Reinforcement (Critical Leak Prevention Work)

The most common failure points on aging roofs were addressed before any field coating was installed:

• Seams and joints: secured (with additional fastening where required) and sealed
• Gaps and cracks: sealed to prevent water entry and movement-related splitting
• Open membrane seams: repaired using thick silicone mastic
• Pipe penetrations: primed as required and sealed with brush-grade silicone
• Curb penetrations and transitions: reinforced by coating vertically and onto the field (“wrap” approach)
• Exposed fasteners: sealed to reduce leak pathways and back-out risk

System Build: Primer & High-Solids Silicone Coating

• Bleed-block primer applied as specified
• High-solids silicone coating installed to the specified thickness to create a monolithic weathering surface
• Final walkthrough completed with a building representative

Why a Silicone Coating System Was Selected

Silicone coatings are commonly used in commercial roof restoration because they perform well under UV exposure, maintain elasticity, and resist long-term weathering. They are frequently selected for low-slope roofs where wet conditions and durability are ongoing concerns.

Silicone is also less prone to blistering due to its permeability to trapped vapor while remaining impermeable to liquid water.

The Results

The goal of this project was not to make an old roof “new,” but to eliminate repeat leak pathways, stabilize aging details, and add a durable protective surface —without the disruption and capital expense of a full tear-off.

After completion, the roof presented as a continuous, reinforced membrane with sealed penetrations, tightened transitions, and a uniform silicone topcoat.

Outcome Summary:

• Repeat leak pathways addressed at seams, penetrations, curbs, and fasteners
• Continuous silicone membrane installed over a prepared substrate
• Roof positioned for extended service life with proactive maintenance

Targeted leak reduction at the source

Rather than chasing symptoms, restoration focused on the most common failure points on aging low-slope systems. These areas were cleaned, reinforced, and sealed before the field coating was installed, reducing entry points for wind-driven rain and ongoing seepage.

A seamless protective surface designed to extend service life

With preparation and detailing complete, the high-solids silicone coating created a monolithic weathering surface that improves UV resistance and helps delay full replacement.

Cleaner maintenance path going forward

The coated surface allows easier visual inspections, documentation, and early correction of minor issues before they become interior disruptions.

Warranty & Risk-Reduction Options

The project included an optional manufacturer labor-and-material warranty pathway with third-party inspection. For many owners, this provides added confidence by pairing installation standards with documented verification, supporting long-term asset planning and risk reduction.

Conclusion

If a roof is aging but still serviceable, a coating restoration can buy time and reduce risk  —but only when details are properly repaired first.

Preparation, detailing, and thickness drive outcomes. Coatings fail early when shortcuts are taken at seams, penetrations, and transitions. Restoration also requires ongoing roof maintenance; the best return comes from routine roof inspections and small corrections before issues spread.

If you manage a commercial facility in Western North Carolina or Upstate South Carolina and your roof is showing signs of age —recurring leaks, seam issues, penetration problems, or general surface fatigue— a silicone coating restoration may be a smart intermediate strategy before full replacement.

Request a commercial roof assessment from WNC Roofing and ask for a coating feasibility review that evaluates substrate condition, moisture presence, detail scope, and warranty pathways. If coating is not appropriate, alternative repair or replacement options can be outlined.