Why a $X replacement
wasn't the answer.
An 85,000 sq ft manufacturing facility in Columbus had an 18-year-old EPDM membrane with active leaks directly over the production floor. $2M in CNC equipment sat beneath the leak field. Two prior patch attempts had failed. Conventional replacement required 5-6 weeks of production shutdown — an estimated $1.8M in lost manufacturing revenue, on top of the $935,000 replacement bid.
Active leaks over $2M in CNC equipment — production insurance deductible exposure with each rainfall event
18-year-old EPDM membrane past rated service life — two previous patch cycles had failed within 6 months
Full tear-off required 5-6 weeks of production shutdown: $1.8M estimated revenue loss, not including the $935K replacement cost
Assessment to warranty
in 6 days.
Substrate Analysis
Infrared survey confirmed EPDM membrane was a Gaco S20 overcoat candidate. Wet insulation in three field areas documented and removed prior to overcoat.
Night & Weekend Scheduling
Application scheduled exclusively during non-production hours. Day shift ran uninterrupted throughout the project.
Gaco S20 Silicone Overcoat
Full overcoat applied to all 85,000 sq ft. Seams re-reinforced. Penetrations detailed and sealed to manufacturer specification.
30-Year Warranty Issuance
Gaco manufacturer warranty registered. Energy performance baseline established for post-installation cooling cost comparison.
The complete picture
for your CFO.
Section 179 estimate based on 35% effective tax rate. Consult your CPA for project-specific tax treatment under IRS Section 179 qualified improvement property rules.
We had CNC equipment sitting under active leaks and a 5-6 week production shutdown on the table if we replaced the roof the conventional way. Certified applied Gaco S20 over the existing EPDM in six days — nights and weekends, around our production schedule. The cooling savings alone, $41,000 in the first summer, are retiring the project cost faster than we projected.
What could your building save?
Every project starts with a free infrared moisture survey and written report. No obligation. If restoration isn’t the right solution for your roof, we’ll tell you.